HOISTING and RIGGING

Safety Manual

Infrastructure Health & Safety Association

5110 Creekbank Rd., Suite 400
Mississauga, Ontario L4W 0A1 Canada
(905) 625-0100
1-800-263-5024
Fax (905) 625-8998
info@ihsa.ca
www.ihsa.ca
Disclaimer
In
Thethecontents
past, members of the
contained in public have used are
this publication printed information
for general that was outdated
information by publication
only. This subsequent
improvements in knowledge and technology. We therefore make the following statement for their
should not be regarded or relied upon as a definitive guide to government regulations or to
protection in future.
safety practices and procedures. The contents of this publication were, to the best of our
knowledge,
The informationcurrent at thehere
presented timewas,
of printing. However,
to the best no representations
of our knowledge, current atoftime
anyofkind are made
printing and is
with regard
intended to the application.
for general accuracy, This
completeness,
publication isornot
sufficiency
a definitive of the tocontents.
guide government The appropriate
regulations or to
regulations and statutes should be consulted. Readers should not act on the information
practices and procedures wholly applicable under every circumstance. The appropriate regulations and
statutes should be consulted. Although the Construction Safety Association
contained herein without seeking specific independent legal advice on their specificof Ontario cannot guarantee
the accuracy of, nor assume liability for, the information presented here, we are pleased to answer
circumstance. The Infrastructure Health & Safety Association is pleased to answer individual
individual requests for counselling and advice.
requests for counselling and advice.

© Infrastructure Health and Safety Association, 1995

Revised, May 1997

Revised, April 2001
© Construction
Revised, JanuarySafety
2007Association of Ontario, 1995
Revised, September
REVISED May 1997 2008
REVISED April 20012009
Revised, September
REVISED January 2007
Second printing,
REVISED August
September 2010
2008
Third printing, August 2011
Fourth printing, March 2012
ISBN-13: 978-0-919465-70-1

ISBN-13: 978-0-919465-70-1
TABLE of CONTENTS

Introduction 1

Section 1: Hoisting and Rigging Hazards 3

Procedures and Precautions 5
Determining Load Weights 15
Weights of Common Materials 17

Section 2: Fibre Ropes, Knots, Hitches 19

Fibre Rope Characteristics 20
Inspection of Fibre Rope 21
Working Load Limit (WLL) 22
Care, Storage, Use 23
Knots and Hitches 26

Section 3: Hardware, Wire Rope, Slings 30

Wire Rope 31
Sling Configurations 43
Sling Angles 49
Centre of Gravity 51
Sling WLLs 53
Sling Types 60
Rigging Hardware 71
Hoisting Tips 72

Section 4: Rigging Tools and Devices 83

Jacks 85
Blocking and Cribbing 88
Rollers 89
Inclined Planes 90
Lever-Operated Hoists 91
Chain Hoists 91
Grip-Action Hoists or Tirfors 93
Electric Hoists and Pendant Cranes 95
Winches 97
Anchorage Points 98

Section 5: Introduction to Crane Operations 103

Responsibilities 105
Basic Types and Configurations 107
Hazards in Crane Operating Areas 122
Working near Powerlines 126
Factors Affecting Crane Capacity 132
Setup Summary 155
Machine Selection 156
Signalling 158
INTRODUCTION
Purpose of this Manual
This manual is intended as a working guide for training workers and supervisors in the fundamentals
of safe rigging and hoisting.

The information covers not only ropes and knots but hoisting equipment from cranes to chainfalls
and rigging hardware from rope clips to spreader beams. Equally important is the attention paid at
every point to correct procedures for inspection, maintenance, and operation.

Knowledge of the equipment and materials with which we work is one of the most important
factors in occupational health and safety. Each item has been designed and developed to serve a
specific purpose. Recognizing its capabilities and limitations not only improves efficiency but
minimizes hazards and helps prevent accidents.

This manual identifies the basic hazards in rigging and hoisting, explains the safeguards necessary
to control or eliminate these hazards, and spells out other essential safety requirements.

The information should be used in conjunction with the applicable regulations by contractors,
supervisors, operators, riggers, and others delivering or receiving instruction in the basics of safe
rigging and hoisting.

Health and Safety Law

Occupational Health and Safety Act
Safety legislation for Ontario construction in general consists of the Occupational Health and
Safety Act, which came into force on 1 October 1979. Its purpose is to protect workers against
health and safety hazards on the job.

The Occupational Health and Safety Act is based on the “internal responsibility” concept for
management and workers. This encourages both groups to work out solutions to health and safety
problems with the guidance of the Ministry of Labour.

The Act provides us with the framework and the tools to achieve a safe and healthy workplace. It
sets out the rights and duties of all parties in the workplace. It establishes procedures for dealing
with job-site hazards and provides for enforcement of the law where compliance has not been
achieved voluntarily.

Over the years the Act has been revised to meet the changing requirements of Ontario’s
workplaces.

1
Regulations

There are various regulations under the Act for construction in particular.

The most extensive is the Construction Regulation (Ontario Regulation 213/91). There are also
special regulations for controlled products under the Workplace Hazardous Materials Information
System (WHMIS) and for designated substances such as asbestos.

Construction regulations are generally based on health and safety problems that have recurred
over the years. In many cases, the regulations have been proposed jointly by management and
labour groups as a means of controlling or eliminating problems that have historically resulted in
fatalities, lost-time injuries, and occupational diseases.

The Construction Regulation has been periodically revised over the years.

Review Ontario’s Occupational Health and Safety Act, the Construction Regulation, and other
applicable health and safety regulations to make sure that you know what to expect from others
on the job – and what others expect from you.

2
Section 1

Hoisting and Rigging Hazards

䡲 Procedures and Precautions

䡲 Determining Load Weights
䡲 Weights of Common Materials

3
Section 1

Hoisting and Rigging Hazards

It is important that workers involved with hoisting and rigging activities are trained in both safety
and operating procedures. Hoisting equipment should be operated only by trained personnel.
The cause of rigging accidents can often be traced to a lack of knowledge on the part of a rigger.
Training programs such as the Infrastructure Health & Safety Association’s Basic Safety Training for
Hoisting and Rigging provide workers with a basic knowledge of principles relating to safe hoisting
and rigging practices in the construction industry.
A safe rigging operation requires the rigger to know
• the weight of the load and rigging hardware
• the capacity of the hoisting device
• the working load limit of the hoisting rope, slings, and hardware.
When the weights and capacities are known, the rigger must then determine how to lift the load
so that it is stable.
Training and experience enable riggers to recognize hazards that can have an impact on a hoisting
operation. Riggers must be aware of elements that can affect hoisting safety, factors that reduce
capacity, and safe practices in rigging, lifting, and landing loads. Riggers must also be familiar with
the proper inspection and use of slings and other rigging hardware.
Most crane and rigging accidents can be prevented by field personnel following basic safe
hoisting and rigging practices. When a crane operator is working with a rigger or a rigging crew, it
is vital that the operator is aware of the all aspects of the lift and that a means of communication
has been agreed upon, including what signals will be used.

4
Elements that can Affect Hoisting Safety
– Working Load Limit (WLL) not known. Don’t assume. Know the working load limits of the
equipment being used. Never exceed these limits.
– Defective components. Examine all hardware, tackle, and slings before use. Destroy
defective components. Defective equipment that is merely discarded may be picked up and
used by someone unaware of its defects.
– Questionable equipment. Do not use equipment that is suspected to be unsafe or
unsuitable, until its suitability has been verified by a competent person.
– Hazardous wind conditions. Never carry out a hoisting or rigging operation when winds
create hazards for workers, the general public, or property. Assess load size and shape to
determine whether wind conditions may cause problems. For example, even though the
weight of the load may be within the capacity of the equipment, loads with large wind-
catching surfaces may swing or rotate out of control during the lift in high or gusting winds.
Swinging and rotating loads not only present a danger to riggers—there is the potential for
the forces to overload the hoisting equipment.
– Weather conditions. When the visibility of riggers or hoist crew is impaired by snow, fog,
rain, darkness, or dust, extra caution must be exercised. For example, operate in “all slow”,
and if necessary, the lift should be postponed. At sub-freezing temperatures, be aware that
loads are likely to be frozen to the ground or structure they are resting on. In extreme cold
conditions avoid shock-loading or impacting the hoist equipment and hardware, which may
have become brittle.
– Electrical contact. One of the most frequent killers of riggers is electrocution. An electrical
path can be created when a part of the hoist, load line, or load comes into close proximity to
an energized overhead powerline. When a crane is operating near a live powerline and the
load, hoist lines, or any other part of the hoisting operation could encroach on the minimum
permitted distance (see table on the next page), specific measures described in the
Construction Regulation must be taken. For example, constructors must have written
procedures to prevent contact whenever equipment operates within the minimum permitted
distance from a live overhead powerline. The constructor must have copies of the procedure
available for every employer on the project.
– Hoist line not plumb. The working
load limits of hoisting equipment apply
only to freely suspended loads on
plumb hoist lines. If the hoist line is not
plumb during load handling, side loads
are created which can destabilize the
equipment and cause structural failure
or tip-over, with little warning.

Wrong. The hoist line must be plumb at all times.

5
Keep the Minimum Distance from Powerlines
Minimum
Normal phase-to-phase voltage rating distance

750 or more volts, but no more than 150,000 volts 3 metres

GER!
DANTOP!
Over 150,000 volts, but no more than 250,000 volts 4.5 metres S
More than 250,000 volts 6 metres

Beware:
The wind can blow powerlines, hoist lines, or your load.
This can cause them to cross the minimum distance.
This crane boom could reach within
the minimum distance.

Factors that Reduce Capacity

The working load limits of hoisting and rigging equipment are based on ideal conditions. Such ideal
circumstances are seldom achieved in the field. Riggers must therefore recognize the factors that
can reduce the capacity of the hoist.
– Swing. The swinging of suspended loads creates additional dynamic forces on the hoist in
addition to the weight of the load. The additional dynamic forces (see point below) are difficult
to quantify and account for, and could cause tip-over of the crane or failure of hoisting
hardware. The force of the swinging action makes the load drift away from the machine,
increasing the radius and side-loading on the equipment. The load should be kept directly
below the boom point or upper load block. This is best accomplished by controlling the load’s
movement with slow motions.
– Condition of equipment. The rated working load limits apply only to equipment and
hardware in good condition. Any equipment damaged in service should be taken out of
service and repaired or destroyed.
– Dynamic forces. The working load limits of rigging and hoisting equipment are determined for
static loads. The design safety factor is applied to account, in part, for the dynamic motions of the
load and equipment. To ensure that the working load limit is not exceeded during operation, allow
for wind loading and other dynamic forces created by the movements of the machine and its load.
Avoid sudden snatching, swinging, and stopping of suspended loads. Rapid acceleration and
deceleration also increases these dynamic forces.
– Weight of tackle. The rated load of hoisting equipment does not account for the weight of
hook blocks, hooks, slings, equalizer beams, and other parts of the lifting tackle. The
combined weight of these items must be added to the total weight of the load, and the
capacity of the hoisting equipment, including design safety factors, must be large enough to
account for the extra load to be lifted.

6
Slings
After the hoist rope, the sling is the most commonly used piece of rigging equipment. Observe the
following precautions with slings.

• Never use damaged slings. Inspect slings regularly to ensure their safety. Check wire rope slings
for kinking, wear, abrasion, broken wires, worn or cracked fittings, loose seizings and splices,
crushing, flattening, and rust or corrosion. Pay special attention to the areas around thimbles
and other fittings.
• Slings should be marked with an identification number and their maximum capacity on a flat
ferrule or permanently attached ring. Mark the capacity of the sling for a vertical load or at an
angle of 45°. Ensure that everyone is aware of how the rating system works.

• Avoid sharp bends, pinching, and crushing. Use loops and thimbles at all times. Corner pads
that prevent the sling from being sharply bent or cut can be made from split sections of large-
diameter pipe, corner saddles, padding, or blocking.

Ensure that Slings are Protected at All Sharp Corners on Heavy Items

For heavy
structural
members.

Radius of contact
should be equal to
1 rope lay.

7
• Never allow wire rope slings, or any wire rope, to lie on the ground for long periods of time or on
damp or wet surfaces, rusty steel, or near corrosive substances.
• Avoid dragging slings out from underneath loads.
• Keep wire rope slings away from flame cutting and electric welding.
• Never make slings from discarded hoist rope.
• Avoid using single-leg wire rope slings with hand-spliced eyes. The load can spin, causing the
rope to unlay and the splice to pull out. Use slings with Flemish Spliced Eyes.

NO!

Never Wrap a Sling Around a Hook

• Never wrap a wire sling completely around a hook. The sharp radius will damage the sling. Use
the eye.

SEVERE BENDING

Do Not Permit Bending Near Any Splice or Attached Fitting

• Avoid bending the eye section of wire rope slings around corners. The bend will weaken the
splice or swaging. There must be no bending near any attached fitting.

8
 If L is greater than S then sling angle is OK.

Check on Sling Angle

• Ensure that the sling angle is always greater than 45° and preferably greater than 60°. When the
horizontal distance between the attachment points on the load is less than the length of the
shortest sling leg, then the angle is greater than 60° and generally safe.

• Multi-leg slings. With slings having more than two legs and a rigid load, it is possible for some
of the legs to take practically the full load while the others merely balance it. There is no way of
knowing that each leg is carrying its fair share of the load.

As a result, when lifting rigid objects with three- or four-leg bridle slings, make sure that at least
two of the legs alone can support the total load. In other words, consider multi-leg slings used
on a rigid load as having only two legs.

When using multi-leg slings to lift loads in which one end is much heavier than the other (i.e.,
some legs simply provide balance), the tension on the most heavily loaded leg(s) is more
important than the tension on the more lightly loaded legs. In these situations, slings are selected
to support the most heavily loaded leg(s). Do not treat each leg as equally loaded (i.e., do not
divide the total weight by the number of legs.) Keep in mind that the motion of the load during
hoisting and travel can cause the weight to shift into different legs. This will result in increases
and decreases on the load of any leg.

9
• When using choker hitches, forcing the eye down towards the load increases tension in the sling,
which can result in rope damage. Use thimbles and shackles to reduce friction on the running line.

Incorrect – Cutting Correct – Use thimbles Incorrect – Shackle Correct – Shackle pin
action of in the eyes. pin bearing cannot turn.
eye splice on running
on running line can
line. work loose.

• Whenever two or more rope eyes must be placed over a hook,

install a shackle on the hook with the shackle pin resting in the
hook and attach the rope eyes to the shackle. This will prevent
the spread of the sling legs from opening up the hook and
prevent the eyes from damaging each other under load.

Whenever 2 or more ropes are to be

Placed Over a Hook – Use a Shackle
10
Rigging, Lifting, and Landing Loads

• Rig loads to prevent any parts from shifting or dislodging during the lift. Suspended loads should
be securely slung and properly balanced before they are set in motion.
• Keep the load under control at all times. Use one or more taglines to prevent uncontrolled
motion.

Use Tag Lines to Control All Loads

• Loads must be safely landed and properly blocked before being unhooked and unslung.
• Lifting beams should be plainly marked with their weight and designed working loads, and
should only be used for their intended purpose.
• Never wrap the hoist rope around the load. Attach the load to only the hook, with slings or other
rigging devices.
• The load line should be brought over the load’s centre of gravity before the lift is started.
• Keep hands away from pinch points as slack is being taken up.
• Wear gloves when handling wire rope.
• Make sure that everyone stands clear when loads are being lifted, lowered, and freed of slings.
As slings are being withdrawn, they may catch under the load and suddenly fly loose.

11
• Before making a lift, check to see that the sling is properly attached to the load.
• Never work under a suspended load.
• Never make temporary repairs to a sling. Procedures for proper repair should be established and
followed.
• Secure or remove unused sling legs of a multi-leg sling before the load is lifted.

• Never point-load a hook unless it is designed and rated for such use.
• Begin a lift by raising the load slightly to make sure that the load is free and that all sling legs are
taking the load.
• Avoid impact loading caused by sudden jerking during lifting and lowering. Take up slack on the
sling gradually. Avoid lifting or swinging the load over workers below.
• When using two or more slings on a load, ensure that they are all made from the same material.
• Prepare adequate blocking before loads are lowered. Blocking can help prevent damage to
slings.

12
Determining Load Weights
A key step in rigging is determining the weight of the load that will be hoisted.

You can obtain the load’s weight from shipping papers, design plans, catalogue data,
manufacturer’s specifications, and other dependable sources. On erection plans, the size of steel
beams is usually provided along with their weight and length. If weight information is not provided,
you will have to calculate it.

Calculating weight

You can calculate the approximate weight of a steel object using a standard weight and applying
the formulas for area and volume. The standard weight for steel is: 1 square foot of steel an inch
thick will weigh about 40 pounds.

Applying that standard weight for steel to calculate the weight of two steel plates measuring
1 1/2” x 3’ x 6’ results in the following:

2 (sheets) x 1.5” (thickness) x 3’ x 6’ (area) x 40 lb (weight per square foot, 1” thick) = 2160 pounds.
[2 x 1.5 x 3 x 6 x 40 = 2160 pounds]

WEIGHT = 40 lbs.

STEEL

13
Calculating the weight of various shapes of steel
To estimate the weight of various shapes of steel, it helps to envision the steel object as a flat
plate—visually separate the parts, or imagine flattening them into rectangles.

Angle iron has a structural shape that can be considered a bent plate. If you flattened the angle
iron, the result is a plate. For example, 5 x 3 x 1/4-inch angle iron would flatten out to
approximately a 1/4-inch plate that is 8 inches wide.

Once you have figured out the flattened size, the volume and weight can be calculated like we did
in the previous section. Since the calculations for the standard weight of steel is expressed in
square feet per inch thickness, the 8-inch width must be divided by 12 to get the fraction of a foot
that it represents. The 1/4” thickness is already expressed as a fraction of one inch. In this case,
the angle iron weighs approximately 6.67 pounds (40 lb x 8” ÷ 12” x 1/4” = 6.67). Multiply this
weight by the length (in feet) to get the total weight.

Plates are often rolled into tanks or other shapes. In order to calculate the weight of a circular or
spherical piece of steel, first you need to determine the square foot area. To determine the square
foot area, you have to figure out the circumference (the distance CIRCUMFERENCE
around the edge of the circle) and the area. To get the circumference
of a circle, multiply the diameter by 3.14.

A stack 6 ft. in diameter would have a circumference of 6 ft. x 3.14, or

18.84 ft. To compute the weight of this stack, if it were 30 ft. high and
made of 3/8 in. plate, mentally unroll it and flatten it out (Fig. 1.1). This
gives a plate 18.84 ft. wide by 30 ft. long by 3/8” thick. The weight is:
18.84 x 30 x 3/8 x 40 = 8,478 Ibs.

The following formula gives the area of circular objects.

radius (r) = diameter divided by 2

area =  r2 ( = 3.14)

AREA = 3.14 x diameter x diameter

2 2

Thus, if the stack had an end cap

3/8” thick and 6 ft. in diameter (see
Fig. 1.2), it would have a surface area:

AREA = 3.14 x 6/2 x 6/2 = 28.3 sq. ft.

and would weigh: 28.3 x 3/8 x 40 = 425 Ibs. (Figure 1.2)

14
 Load Weight Determination
Figure 1.2

For other materials the weights are normally based on their weight per cubic foot, so you have to
determine how many cubic feet of material (the volume) you are hoisting in order to estimate the weight.

For example, suppose you have a bundle of spruce lumber to hoist and the bundle is 12 ft. long,
3’ high and 4’ wide. (Fig. 1.3) The weight per cubic foot from Table 1.2 is 28 lbs., so the weight of
this bundle is 12 x 3 x 4 x 28 = 4,032 Ibs.

Load Weight Determination

Figure 1.3

The time taken to calculate the approximate weight of any object, whether steel, plates, columns,
girders, castings, bedplates, etc., is time well spent and may save a serious accident through
failure of lifting gear. The following tables of weights of various materials (Tables 1.1, 1.2, 1.3)
should enable any rigger to compute the approximate weight of a given load. When in doubt, do
not lift the load. Seek assistance from others who know, or can help determine, the load’s weight.

In hoisting and rigging applications, sometimes you will need to account for resistive forces. One
example is when hoist lines are being used over pulleys to change the direction of the hoist line.
Another example is when loads are being pulled along a surface. Pulleys and rollers on the ground
will add some resistance that must be included in load calculations.

Calculating pull required

Horizontal moves require relatively little force to move. Generally, the force to move the load on a
smooth, clean and flat surface, using rollers in excellent condition will be about 5% of the load
weight. This is roughly the force required to overcome friction and start the load moving. To
calculate the amount of pull you need to move up an incline, use the following method.

Caution:
Though widely used because of its simplicity, this method provides an approximate value that is higher than
the actual force required. The formula is more accurate for slight inclines (1:5) than steep inclines (1:1). Table 1
shows the difference between the actual pull required and the pull calculated. This simplified method is
adequate for most applications. You may need more accurate calculations for large loads.

15
Exercise
Calculate the force of the load in the following situation. A 15-ton compressor is to be lowered 10
feet. A ramp has been built with a horizontal run of 50 feet.

Formula
F (total force) = W x H ÷ L (lift force) + .05W (horizontal force or resistance)

F = Force that the winch must overcome, H = Height, L = Length,

W = Weight of Load

The slope of the ramp is 10 divided by 50 or 1/5th; so the force required is then 15 tons times 1/5th,
plus 5% of 15 tons to allow for friction.

This is equal to 3 tons plus .75 tons. Therefore the required pull is 3.75 tons.

With a winch, use its rated capacity for vertical lifting rather than its horizontal capacity so that you
maintain an adequate margin of safety.

Table 2 lists some examples of coefficients of friction. Note that some of the combinations of
materials have a considerable range of values.

16
 Table 1.1 – APPROXIMATE WEIGHT PER FOOT OF LENGTH
OF ROUND STEEL BARS AND RODS

Diameter Weight (Lbs.) Diameter Weight (Lbs.)

(inches) Per Ft. of Length (inches) Per Ft. of Length

3/16 .094 1 3/8 5.05

1/4 .167 1 1/2 6.01
5/16 .261 1 5/8 7.05
3/8 .376 1 3/4 8.18
7/16 .511 1 7/8 9.39
1/2 .668 2 10.68
9/16 .845 2 1/8 12.06
5/8 1.04 2 1/4 13.52
3/4 1.50 2 3/8 15.06
7/8 2.04 2 1/2 16.69
1 2.67 2 5/8 18.40
1 1/8 3.38 2 3/4 20.20
1 3/16 3.77 2 7/8 22.07
1 1/4 4.17 3 24.03

Table 1.2 –WEIGHTS OF MATERIAL (Based on Volume)

Approximate Approximate
Weight Weight
Material Material
Lbs. Per Lbs. Per
Cubic Foot Cubic Foot

METALS TIMBER, AIR-DRY

Aluminum 165 Cedar 22
Brass 535 Fir, Douglas, seasoned 34
Bronze 500 Fir, Douglas, unseasoned 40
Copper 560 Fir, Douglas, wet 50
Iron 480 Fir, Douglas, glue laminated 34
Lead 710 Hemlock 30
Steel 490 Pine 30
Tin 460 Poplar 30
MASONRY Spruce 28
Ashlar masonry 140-160 LIQUIDS
Brick masonry, soft 110 Alcohol, pure 49
Brick masonry, common (about Gasoline 42
3 tons per thousand) 125 Oils 58
Brick masonry, pressed 140 Water 62
Clay tile masonry, average 60 EARTH
Rubble masonry 130-155 Earth, wet 100
Concrete, cinder, haydite 100-110 Earth, dry (about 2050 Ibs.
Concrete, slag 130 per cu. yd.) 75
Concrete, stone 144 Sand and gravel, wet 120
Concrete, stone, reinforced Sand and gravel, dry 105
(4050 Ibs. per cu. yd.) 150 River sand (about 3240 Ibs.
ICE AND SNOW per cu. yd.) 120
Ice 56 VARIOUS BUILDING
Snow, dry, fresh fallen 8 MATERIALS
Snow, dry, packed 12-25 Cement, portland, loose 94
Snow, wet 27-40 Cement, portland, set 183
MISCELLANEOUS Lime, gypsum, loose 53-64
Asphalt 80 Mortar, cement-lime, set 103
Tar 75 Crushed rock (about 2565 Ibs
Glass 160 per cu. yd.) 90-110
Paper 60

17
 Table 1.3 – WEIGHTS OF MATERIALS (Based on Surface Area)

Approximate Approximate
Weight Weight
Material Material
Lbs. Per Lbs. Per
Square Foot Square Foot

CEILINGS FLOORING
(Per Inch of Thickness) (Per Inch of Thickness)
Plaster board 5 Hardwood 5
Acoustic and fire resistive tile 2 Sheathing 2.5
Plaster, gypsum-sand 8 Plywood, fir 3
Plaster, light aggregate 4 Wood block, treated 4
Plaster, cement sand 12 Concrete, finish or fill 12
ROOFING Mastic base 12
Three-ply felt and gravel 5.5 Mortar base 10
Five-ply felt and gravel 6.5 Terrazzo 12.5
Three-ply felt, no gravel 3 Tile, vinyl inch 1.5
Five-ply felt, no gravel 4 Tile, linoleum 3/16 inch 1
Shingles, wood 2 Tile, cork, per 1/16 inch 0.5
Shingles, asbestos 3 Tile, rubber or asphalt 3/16 inch 2
Shingles, asphalt 2.5 Tile, ceramic or quarry 3/4 inch 11
Shingles, 1⁄4 inch slate 10 Carpeting 2
Shingles, tile 14 DECKS AND SLABS
PARTITIONS Steel roof deck 1 1/2” – 14 ga. 5
Steel partitions 4 – 16 ga. 4
Solid 2” gypsum-sand plaster 20 – 18 ga. 3
Solid 2” gypsum-light agg. plaster 12 – 20 ga. 2.5
Metal studs, metal lath, 3/4” – 22 ga. 2
plaster both sides 18 Steel cellular deck 1 1/2” – 12/12 ga. 11
Metal or wood studs, plaster – 14/14 ga. 8
board and 1/2” plaster both sides 18 – 16/16 ga. 6.5
Plaster 1/2” 4 – 18/18 ga. 5
Hollow clay tile 2 inch 13 – 20/20 ga. 3.5
3 inch 16 Steel cellular deck 3” – 12/12 ga. 12.5
4 inch 18 – 14/14 ga. 9.5
5 inch 20 – 16/16 ga. 7.5
6 inch 25 – 18/18 ga. 6
Hollow slag concrete block 4 inch 24 – 20/20 ga. 4.5
6 inch 35 Concrete, reinforced, per inch 12.5
Hollow gypsum block 3 inch 10 Concrete, gypsum, per inch 5
4 inch 13 Concrete, lightweight, per inch 5-10
5 inch 15.5 MISCELLANEOUS
6 inch 16.5 Windows, glass, frame 8
Solid gypsum block 2 inch 9.5 Skylight, glass, frame 12
3 inch 13 Corrugated asbestos 1/4 inch 3.5
MASONRY WALLS Glass, plate 1/4 inch 3.5
(Per 4 Inch of Thickness) Glass, common 1.5
Brick 40 Plastic sheet 1/4 inch 1.5
Glass brick 20 Corrugated steel sheet, galv. – 12 ga. 5.5
Hollow concrete block 30 – 14 ga. 4
Hollow slag concrete block 24 – 16 ga. 3
Hollow cinder concrete block 20 – 18 ga. 2.5
Hollow haydite block 22 – 20 ga. 2
Stone, average 55 – 22 ga. 1.5
Bearing hollow clay tile 23 Wood Joists – 16” ctrs. 2 x 12 3.5
2 x 10 3
2x8 2.5
Steel plate (per inch of thickness) 40

18
Section 2

Fibre Ropes, Knots, Hitches

䡲 Fibre Rope Characteristics

䡲 Inspection of Fibre Rope
䡲 Working Load Limit (WLL)
䡲 Care, Storage, Use
䡲 Knots
䡲 Hitches

19
Section 2
Fibre Ropes, Knots, Hitches

Fibre rope is a commonly used tool which has many applications in daily hoisting and rigging
operations.

Readily available in a wide variety of synthetic and natural fibre materials, these ropes may be used as

• slings for hoisting materials

• handlines for lifting light loads
• taglines for helping to guide and control loads.

There are countless situations where the rigger will be required to tie a safe and reliable knot or
hitch in a fibre rope as part of the rigging operation. Fastening a hook, making eyes for slings, and
tying on a tagline are a few of these situations.

This section addresses the correct selection, inspection, and use of fibre rope for hoisting and
rigging operations. It also explains how to tie several knots and hitches.

Characteristics
The fibres in these ropes are either natural or synthetic. Natural fibre ropes should be used
cautiously for rigging since their strength is more variable than that of synthetic fibre ropes and they
are much more subject to deterioration from rot, mildew, and chemicals.

Polypropylene is the most common fibre rope used in rigging. It floats but does not absorb water.
It stretches less than other synthetic fibres such as nylon. It is affected, however, by the ultraviolet
rays in sunlight and should not be left outside for long periods. It also softens with heat and is not
recommended for work involving exposure to high heat.

Nylon fibre is remarkable for its strength. A nylon rope is considerably stronger than the same size
and construction of polypropylene rope. But nylon stretches and hence is not used much for
rigging. It is also more expensive, loses strength when wet, and has low resistance to acids.

Polyester ropes are stronger than polypropylene but not so strong as nylon. They have good
resistance to acids, alkalis, and abrasion; do not stretch as much as nylon; resist degradation from
ultraviolet rays; and don’t soften in heat.

All fibre ropes conduct electricity when wet. When dry, however, polypropylene and polyester have
much better insulating properties than nylon.

20
Inspection

Inspect fibre rope regularly and before each use. Any estimate of its capacity should be based on
the portion of rope showing the most deterioration.

Check first for external wear and cuts, variations in the size and shape of strands, discolouration,
and the elasticity or “life” remaining in the rope.

Untwist the strands without kinking or distorting them. The inside of the rope should be as bright
and clean as when it was new. Check for broken yarns, excessively loose strands and yarns, or an
accumulation of powdery dust, which indicates excessive internal wear between strands as the
rope is flexed back and forth in use.

If the inside of the rope is dirty, if strands have started to unlay, or if the rope has lost life and
elasticity, do not use it for hoisting.

Check for distortion in hardware. If thimbles are loose in the eyes, seize the eye to tighten the
thimble (Figure 2.1). Ensure that all splices are in good condition and all tucks are done up (Figure
2.2).

If rope or eye Whip rope to Check for To secure

stretches – tighten up Tucks splice –
thimble will rock. thimble in eye. popping use
free. whipping.
Figure 2.1 Figure 2.2

21
Working Load Limit
The maximum force that you should load a component is the working load limit (WLL). The WLL
incorporates a safety factor (SF). The SF provides additional protection above the manufacturer’s
design factor (DF). The design factor is the safety factor to which the manufacturer builds. The SF
and DF do not provide added capacity. You must never exceed the WLL.

Let’s calculate the WLL of a chain or gin wheel rated at 1000 pounds with a manufacturer’s DF of 3.

Note: Section 172 (1) (d) of the Construction Regulation requires a SF of 5.

This requirement is greater than our DF, so the capacity must be
reduced accordingly.

WLL = 1000 pounds (rated capacity) x 3 (DF) / 5 (SF)

WLL = 600 pounds

In this example, the chain or gin wheel has a stamped capacity of 1000 pounds, but, in compliance
with the Construction Regulation, it can safely lift a maximum capacity of 600 pounds.

Fibre Rope Selection

Select the size and type of rope to use based on manufacturer’s information; conditions of use;
and the degree of risk to life, limb, and property. The WLL of fibre rope is determined by multiplying
the working load (WL) by the SF. The minimum breaking strength (MBS) is the force at which
a new rope will break.

The manufacturer’s DF provides a layer of safety that has been determined by the manufacturer.
The SF, if greater than the DF, adds an additional layer of safety to meet the requirements of users
and regulators. Together, these added layers of safety provide protection above the MBS to
account for reduced capacity due to

• wear, broken fibres, broken yarns, age

• variations in construction size and quality
• shock loads
• minor inaccuracies in load weight calculations
• variances in strength caused by wetness, mildew, and degradation
• yarns weakened by ground-in or other abrasive contaminants.

If you notice rope that is defective or damaged, cut it up to prevent it from being used for hoisting.

Let’s calculate the WLL of a rope to lift a WL of 250 pounds.

Note: Section 172 (1) (d) of the Construction Regulation requires a minimum SF of 5.
For more critical lifts that could risk life, limb, or property, a SF of 10 to 15 may
be necessary.

WLL = 250 pounds (WL) x 5 (SF)

WLL = 1,250 pounds

In this example, to meet the WLL you must use a rope with an MBS of 1,250 to hoist or lower
a WL of 250 pounds. See manufacturers’ specifications to select the appropriate type of rope.

Similar to synthetic slings, you should only use clearly identified rope for hoisting. Identify all
new rope by attaching a strong label showing the manufacturer’s information.

22
Care

• To unwind a new coil of fibre rope, lay it flat with the inside end closest to the floor. Pull the inside
end up through the coil and unwind counterclockwise.
• After use, recoil the rope clockwise. Keep looping the rope over your left arm until only about 15
feet remain. Start about a foot from the top of the coil and wrap the rope about six times around
the loops. Then use your left hand to pull the bight back through the loops and tie with a couple
of half-hitches to keep the loops from uncoiling ( Figure 2.5).

Figure 2.5

• Remove kinks carefully. Never try to pull them straight. This will severely damage the rope and
reduce its strength.

• When a fibre rope is cut, the ends must be bound or whipped to keep the strands from
untwisting. Figure 2.6 shows the right way to do this.

Figure 2.6

23
Storage

• Store fibre ropes in a dry cool room with good air circulation – temperature 10-21°C (50-70°F)
humidity 40-60%.

• Hang fibre ropes in loose coils on large diameter wooden pegs well above the floor (Figure 2.7).

Figure 2.7

• Protect fibre ropes from weather, dampness, and sunlight. Keep them away from exhaust gases,
chemical fumes, boilers, radiators, steam pipes, and other heat sources.
• Let fibre ropes dry before storing them. Moisture hastens rot and causes rope to kink easily. Let
a frozen rope thaw completely before you handle it. Otherwise fibres can break. Let wet or frozen
rope dry naturally.
• Wash dirty ropes in clean cool water and hang to dry.

Use

• Never overload a rope. Apply the design factor of 5 (10 for ropes used to support or hoist
personnel). Then make further allowances for the rope’s age and condition.
• Never drag a rope along the ground. Abrasive action will wear, cut, and fill the outside surfaces
with grit.
• Never drag a rope over rough or sharp edges or across itself. Use softeners to protect rope at
the sharp comers and edges of a load.
• Avoid all but straight line pulls with fibre rope. Bends interfere with stress distribution in fibres.
• Always use thimbles in rope eyes. Thimbles cut down on wear and stress.
• Keep sling angles at more than 45°. Lower angles can dramatically increase the load on each
leg (Figure 2.8). The same is true with wire rope slings.

24
• Never use fibre rope near welding or flame cutting. Sparks and molten metal can cut through the
rope or set it on fire.
• Keep fibre rope away from high heat. Don’t leave it unnecessarily exposed to strong sunlight,
which weakens and degrades the rope.
• Never couple left-lay rope to right-lay.
• When coupling wire and fibre ropes, always use metal thimbles in both eyes to keep the wire
rope from cutting the fibre rope.
• Make sure that fibre rope used with tackle is the right size for the sheaves. Sheaves should have
diameters at least six – preferably ten – times greater than the rope diameter.

Figure 2.8

25
Knots

Wherever practical, avoid tying knots in rope. Knots, bends, and hitches reduce rope strength
considerably. Just how much depends on the knot and how it is applied. Use a spliced end with a
hook or other standard rigging hardware such as slings and shackles to attach ropes to loads.

In some cases, however, knots are more practical and efficient than other rigging methods, as for
lifting and lowering tools or light material.

For knot tying, a rope is considered to have three parts (Figure 2.9).

Bight

End

Standing Part
Figure 2.9

The end is where you tie the knot. The standing part is inactive. The bight is in between.

Following the right sequence is essential in tying knots. Equally important is the direction the end
is to take and whether it goes over, under, or around other parts of the rope.

There are overhand loops, underhand loops, and turns (Figure 2.10).

Overhand Loop Underhand Loop Turn

Figure 2.10

WARNING – When tying knots, always follow the directions over and under precisely. If one part
of the rope must go under another, do it that way. Otherwise an entirely different knot – or no knot
at all – will result.

Once knots are tied, they should be drawn up slowly and carefully to make sure that sections
tighten evenly and stay in proper position.

26
Bowline

Never jams or slips when properly tied. A universal knot if properly tied and untied. Two interlocking
bowlines can be used to join two ropes together. Single bowlines can be used for hoisting or hitching
directly around a ring.

Bowline on the Bight

Used to tie a bowline in the middle of a line or to make a set of double-leg spreaders for lifting pipe.

Bowline

27
Pipe Hitch

Reef or Square Knot

Can be used for tying two ropes of the same diameter together. It is unsuitable for wet or slippery
ropes and should be used with caution since it unties easily when either free end is jerked. Both
live and dead ends of the rope must come out of the loops at the same side.

Two Half Hitches Two

Half
Two half hitches, which can be quickly tied, are reliable Hitches
and can be put to almost any general use.

Running Bowline
The running bowline is mainly used for hanging objects
with ropes of different diameters. The weight of the
object determines the tension necessary for the knot to
grip.

Make an overhand loop with the end of the rope held

toward you (1). Hold the loop with your thumb and
fingers and bring the standing part of the rope back so
that it lies behind the loop (2). Take the end of the rope
in behind the standing part, bring it up, and feed it
through the loop (3). Pass it behind the standing part at
the top of the loop and bring it back down through the
loop (4).

Running Bowline

28
Figure-Eight Knot
This knot is generally tied at the end of a rope to temporarily prevent the strands from unlaying.
The figure-eight knot can be tied simply and quickly and will not jam as easily as the overhand knot.
It is also larger, stronger, and does not injure the rope fibres. The figure-eight knot is useful in
preventing the end of a rope from slipping through a block or an eye.

To tie the figure-eight knot, make an underhand loop (1). Bring the end around and over the
standing part (2). Pass the end under and then through the loop (3). Draw up tight (4).

Figure Eight Knot

29
Section 3

Hardware, Wire Rope, Slings

䡲 Wire Rope
䡲 Sling Configurations
䡲 Sling Angles
䡲 Centre of Gravity
䡲 Sling WLLs
䡲 Sling Types
䡲 Rigging Hardware
䡲 Hoisting Tips

30
Section 3

Hardware, Wire Rope, Slings

The rigger must be able to rig the load to ensure its stability when lifted. This requires a knowledge
of safe sling configurations and the use of related hardware such as shackles, eyebolts, and wire
rope clips.

Determining the working load limits of the rigging equipment as well as the weight of the load is a
fundamental requirement of safe rigging practice.

Do not use any equipment that is suspected to be unsafe or unsuitable until its suitability has been
verified by a competent person.

The working load limits of all hoisting equipment and rigging hardware are based on almost ideal
conditions seldom achieved in the field. It is therefore important to recognize the factors such as
wear, improper sling angles, point loading, and centre of gravity that can affect the rated working
load limits of equipment and hardware.

This section describes the selection and safe use of various types of slings and different kinds of
rigging hardware. Subjects include factors that can reduce capacity, inspection for signs of wear,
calculating safe sling angles, and requirements for slings and hardware under the Regulations for
Construction Projects.

Wire Rope

Selection
Proper rope selection will protect workers, the public, and property from harm and will get the job
done well. An experienced rigger will be familiar with hoisting hazards and will have the best
knowledge base for selecting the most appropriate rope for a specific lift. Some of the main
aspects to consider are strength, diameter, grade, and the type of construction.

Wire Rope for Crane Hoists

The following are requirements when selecting wire rope for crane hoists:
1. The main hoisting rope must possess enough strength to take the maximum load that may be
applied.
2. Wire ropes that are supplied as rigging on cranes must have the following design factors:
• live or running ropes that wind on drums or pass over sheaves
- 3.5 to 1
- 5.0 to 1 when on a tower crane
• pendants or standing ropes
- 3.0 to 1

3. All wire rope must be

• steel wire rope of the type, size, grade, and construction recommended by the
manufacturer of the crane

31
 • compatible with the sheaves and drum of the crane
• lubricated to prevent corrosion and wear.
4. The rope must not be spliced.
5. The rope must have its end connections securely fastened and kept with at least three full turns
on the drum.
6. Rotation-resistant wire rope must not be used as cable for boom hoist reeving and pendants, or
where an inner wire or strand is damaged or broken.
A properly selected rope will
• withstand repeated bending without failure of the wire strands from fatigue
• resist abrasion
• withstand distortion and crushing
• resist rotation
• resist corrosion.

Types of Construction
The number of wires in a rope is an important factor in determining a rope’s characteristics. But
the arrangement of the wires in the strand is also important.

Basic Types
The four basic constructions are illustrated in Figure 1 :
1. Ordinary – all wires are the same size.
2. Warrington – outer wires are alternately larger and smaller.
3. Filler – small wires fill spaces between larger wires.
4. Seale – wires of outer layer are larger diameter than wires of inner layer.

On ropes of Ordinary construction the strands are built in layers. The basic seven-wire strand
consists of six wires laid around a central wire. A nineteen-wire strand is constructed by adding a
layer of twelve wires over a seven-wire strand. Adding a third layer of eighteen wires results in a
37-wire strand.
In this type of construction the wires in each layer have different lay lengths. This means that the
wires in adjacent layers contact each other at an angle. When the rope is loaded the wires rub
against each other with a sawing action. This causes eventual failure of the wires at these points.

32
BASIC WIRE ROPE CONSTRUCTIONS
Figure 1

33
Wire Rope Inspection
It is essential to have a well-planned program of regular inspection carried out by an experienced
inspector.
All wire rope in continuous service should be checked daily during normal operation and inspected
on a weekly basis. A complete and thorough inspection of all ropes in use must be made at least
once a month. Rope idle for a month or more should be given a thorough inspection before it is
returned to service.
A record of each rope should include date of installation, size, construction, length, extent of
service and any defects found.
The inspector will decide whether the rope must be removed from service. His decision will be
based on:

1. details of the equipment on which the rope has been used,

2. maintenance history of the equipment,
3. consequences of failure, and
4. experience with similar equipment.
Conditions such as the following should be looked for during inspection.

Broken Wires
Occasional wire breaks are normal for most ropes and are not critical provided they are at well
spaced intervals. Note the area and watch carefully for any further wire breaks. Broken wire ends
should be removed as soon as possible by bending the broken ends back and forth with a pair of
pliers. This way broken ends will be left tucked between the strands.
Construction regulations under The Occupational Health and Safety Act establish criteria for
retiring a rope based on the number of wire breaks.

Worn and Abraded Wires

Abrasive wear causes the outer wires to become “D” shaped. These worn areas are often shiny in
appearance (Figure 2). The rope must be replaced if wear exceeds 1/3 of the diameter of the wires.

Reduction in Rope Diameter

Reduction in rope diameter can be caused by abrasion Section
through
of outside wires, crushing of the core, inner wire failure, worn
or a loosening of the rope lay. All new ropes stretch portion
slightly and decrease in diameter after being used.

Enlarged
view of
single strand

When the surface wires are worn by 1/3 or

more of their diameter, the rope must be
replaced.

Figure 2

34
Snagged wires resulting from drum crushing

Rope that has been jammed after jumping off

sheave

Rope subjected to drum crushing. Note the

distortion of the individual wires and displacement
from their original postion. This is usually caused
by the rope scrubbing on itself.
Localized crushing Drum crushing
of rope

With no more than 2 layers on drum, With more than 2 layers on drum, there is danger
use any kind of rope. of crushing. Use larger rope or IWRC rope.

CRUSHED, JAMMED AND FLATTENED STRANDS

Figure 3

35
Rope Stretch
All steel ropes will stretch during initial periods of use. Called “constructional stretch”, this condition
is permanent. It results when wires in the strands and strands in the rope seat themselves under
load. Rope stretch can be recognized by increased lay length. Six-strand ropes will stretch about
six inches per 100 feet of rope while eight-strand ropes stretch approximately 10 inches per 100
feet. Rope stretched by more than this amount must be replaced.

Corrosion
Corrosion is a very dangerous condition because it can develop inside the rope without being seen.
Internal rusting will accelerate wear due to increased abrasion as wires rub against one another.
When pitting is observed, consider replacing the rope. Noticeable rusting and broken wires near
attachments are also causes for replacement. Corrosion can be minimized by keeping the rope
well lubricated.

Crushed, Flattened or Jammed Strands

These dangerous conditions require that the rope be replaced (Figure 3). They are often the result
of crushing on the drum.

High Stranding and Unlaying

These conditions will cause the other strands to become overloaded. Replace the rope or renew
the end connection to reset the rope lay (Figure 4).

HIGH STRANDING
Figure 4

36
Bird Caging
Bird caging is caused by the rope being twisted or by a sudden release of an overload (Figure 5 ).
The rope, or the affected section, must be replaced.

Multi-strand rope “birdcages” because of torsional unbalance.

Typical of buildup seen at anchorage end of multi-fall crane application.

A birdcage caused by sudden release of tension

and resulting rebound of rope from overloaded condition.
These strands and wires will not return to their original positions.

A birdcage which has been forced through a tight sheave.

BIRD CAGING
Figure 5

37
Kinks
Kinking is caused by Ioops that have been drawn too tightly as a result of improper handling (Figure
6). Kinks are permanent and will require that the rope, or damaged section, be taken out of service.

Core Protrusion
Core protrusion can be caused by shock loads and/or torsional imbalance (Figure 7). This condition
requires that the rope be taken out of service.

Electrical Contact
Rope subjected to electrical contact will have wires that are fused, discoloured or annealed and
must be removed from service.

An open kink like this is often caused by improper

handling and uncoiling as shown.

These ropes show the severe damage resulting from the use of kinked ropes.
Local wear, distortion, misplaced wires, and early failure are inevitable.
ROPE KINKS
Figure 6

Core protrusion as a result

of torsional unbalance
created by shock loading

Protrusion of IWRC
from shock loading

CORE PROTRUSION
Figure 7

38
Figure 8 illustrates examples of rope damage, while Table 6 identifies likely causes of typical faults.

Narrow path of wear resulting in fatigue fractures caused

by working in a grossly oversized groove or over small Breakup of IWRC from high stress. Note nicking of wires in
support rollers. outer strands

Two parallel paths of broken wires indicate bending Wire fractures at the strand or core interface, as distinct
through an undersize groove in the sheath. from crown fractures, caused by failure of core support.

Fatigue failure of wire rope subjected to heavy loads over

small sheaves. In addition to the usual crown breaks, there Wire rope shows severe wear and fatigue from running
are breaks in the valleys of the strands caused by strand over small sheaves with heavy loads and constant
nicking from overloading. abrasion.

Wire rope that has jumped a sheave. The rope is deformed

Rope failing from fatigue after bending over small sheaves. into a curl as though bent around a round shaft.

Mechanical damage due to rope movement over sharp

edge under load. Rope break due to excessive strain.

TYPICAL ROPE DAMAGE (continued on the next page)

Figure 8

39
 Rapid appearance of many broken wires.
A single strand removed from a wire rope subjected
to “strand nicking”. This condition is the result of
adjacent strands rubbing against one another and is
usually caused by core failure due to continued
operation of a rope under high tensile load. The
ultimate result will be individual wire breaks in the
Wear and damage on one side of rope. valleys of the strands.

TYPICAL ROPE DAMAGE

Figure 8 (continued)

TABLE 6
FAULT POSSIBLE CAUSE FAULT POSSIBLE CAUSE
Accelerated Wear Severe abrasion from being dragged over the Broken Wires or Improper alignment.
ground or obstructions. Undue Wear on Damaged sheaves and drums.
Rope wires too small for application or wrong One Side of Rope
construction or grade.
Poorly aligned sheaves.
Large fleet angle.
Worm sheaves with improper groove size or Broken Wires Near Rope vibration.
shape. Fittings
Sheaves, rollers and fairleads having rough wear
surfaces.
Stiff or seized sheave bearings. Burns Sheave groove too small.
High bearing and contact pressures. Sheaves too heavy.
Sheave bearings seized.
Rope dragged over obstacle.

Rapid Appearance Rope is not flexible enough. Rope Core Charred Excessive heat.
of Broken Wires Sheaves, rollers, drums too small in diameter.
Overload and shock load.
Excessive rope vibration. Corrugation and Rollers too soft.
Rope speed too high. Excessive Wear Sheave and drum material too soft.
Kinks that have formed and been straightened
out.
Crushing and flattening of the rope. Distortion of Lay Rope improperly cut.
Reverse bends. Core failure.
Sheave wobble. Sheave grooves too big.

Pinching and Sheave grooves too small.

Crushing

Rope Broken Off Overload, shock load. Rope Chatters Rollers too small.
Square Kink.
Broken or cracked sheave flange.

Strand Break Overload, shock load. Rope Unlays Swivel fittings on Lang Lay ropes.
Local wear. Rope dragging against stationary object.
Slack in 1 or more strands.
Crushing and Nicking Rope struck or hit during handling.

Corrosion Inadequate lubricant. High Stranding Fittings improperly attached.

Improper type of lubricant. Broken strand.
Improper storage. Kinks, dog legs.
Exposure to acids or alkalis. Improper seizing.

Kinks, Dog Legs, Improper installation. Reduction in Broken core.

Distortions Improper handling. Diameter Overload.
Corrosion.
Severe wear.

Excessive Wear Kinks or bends in rope due to improper handling Bird Cage Sudden release of load.
in Spots in service or during installation.
Vibration of rope on drums or sheaves.

Crushing and Overload, shock load. Strand Nicking Core failure due to continued operation under high
Flattening Uneven spooling. load.
Cross winding.
Too much rope on drum.
Loose bearing on drum.
Faulty clutches.
Rope dragged over obstacle.

Stretch Overload. Core Protrusion Shock loading.

Untwist of Lang Lay ropes. Disturbed rope lay.
Rope unlays.
Load spins.

40
Procedures and Precautions with Wire Rope

• Ensure that the right size and construction of rope is used for the job.
• Inspect and lubricate rope regularly according to manufacturer’s guidelines.
• Never overload the rope. Minimize shock loading. To ensure there is no slack in the rope, start
the load carefully, applying power smoothly and steadily.
• Take special precautions and/or use a larger size rope whenever
- the exact weight of the load is unknown
- there is a possibility of shock loading
- conditions are abnormal or severe
- there are hazards to personnel.
• Use softeners to protect rope from corners and sharp edges.
• Avoid dragging rope out from under loads or over obstacles.
• Do not drop rope from heights.
• Store all unused rope in a clean, dry place.
• Never use wire rope that has been cut, kinked, or crushed.
• Ensure that rope ends are properly seized.
• Use thimbles in eye fittings at all times.
• Prevent loops in slack lines from being pulled tight and kinking. If a loop forms, don’t pull it out
— unfold it. Once a wire rope is kinked, damage is permanent. A weak spot will remain no matter
how well the kink is straightened out.
• Check for abnormal line whip and vibration.
• Avoid reverse bends.
• Ensure that drums and sheaves are the right diameter for the rope being used.
• Ensure that sheaves are aligned and that fleet angle is correct.
• Sheaves with deeply worn or scored grooves, cracked or broken rims, and worn or damaged
bearings must be replaced.
• Ensure that rope spools properly on the drum. Never wind more than the correct amount of rope
on any drum. Never let the rope cross-wind.

41
Slings

General
Slings are often severely worn and abused in construction. Damage is caused by:
• failure to provide blocking or softeners between slings and load, thereby allowing sharp edges
or comers of the load to cut or abrade the slings
• pulling slings out from under loads, leading to abrasion and kinking
• shock loading that increases the stress on slings that may already be overloaded
• traffic running over slings, especially tracked equipment.

Because of these and other conditions, as well as errors in calculating loads and estimating sling
angles, it is strongly recommended that working load limits be based on a design factor of at least
5:1.

For the same reasons, slings must be carefully inspected before each use.

Sling Angles
The rated capacity of any sling depends on its size, its
configuration, and the angles formed by its legs with the
horizontal.

For instance, a two-leg sling used to lift 1000 pounds

will have a 500-pound load on each leg at a sling angle
of 90°. The load on each leg will go up as the angle goes
down. At 30° the load will be 1000 pounds on each leg!
See Figure 9.

Keep sling angles greater than 45° whenever possible.

The use of any sling at an angle lower than 30° is
extremely hazardous. This is especially true when an
error of only 5° in estimating the sling angle can be so
dangerous.

Sling Configurations
Slings are not only made of various material such as
wire rope and nylon web. They also come in various
configurations for different purposes. Common
configurations are explained on the following pages.

Figure 9

42
Sling Configurations

The term “sling” covers a wide variety of configurations for fibre ropes, wire ropes, chains and
webs. Correct application of slings commonly used in construction will be explained here because
improper application can be dangerous.
The Single Vertical Hitch (Figure 10) supports a load by a single vertical part or leg of the sling.
The total weight of the load is carried by a single leg, the sling angle is 90° (sling angle is measured
from the horizontal) and the weight of the load can equal the working load limit of the sling and
fittings. End fittings can vary but thimbles should be used in the eyes. The eye splices on wire
ropes should be Mechanical-Flemish Splices for best security.

SINGLE VERTICAL HITCH

Figure 10

The single vertical hitch must not be used for lifting loose material, lengthy material or anything
difficult to balance. This hitch provides absolutely no control over the load because it permits
rotation. Use single vertical hitches on items equipped with lifting eyebolts or shackles.
Bridle Hitch (Figs 11, 13.). Two, three or four single hitches can be used together to form a bridle
hitch for hoisting an object with the necessary lifting lugs or attachments. Used with a wide
assortment of end fittings, bridle hitches provide excellent load stability when the load is
distributed equally among the legs, the hook is directly over the load’s centre of gravity and the
load is raised level. To distribute the load equally it may be necessary to adjust the leg lengths with
turnbuckles. Proper use of a bridle hitch requires that sling angles be carefully measured to ensure
that individual legs are not overloaded.

Figure 11
43
Because the load may not be distributed evenly when a four-leg sling lifts a rigid load, assume that
the load is carried by two of the legs only and “rate” the four-leg sling as a two-leg sling.

NOTE: Load may be

carried by only 2 legs
while the other legs
merely balance it.

4-LEG BRIDLE HITCH

Figure 13

The Single Basket Hitch (Figure 14) is used to support a load by attaching one end of the sling to
the hook, then passing the other end under the load and attaching it to the hook. Ensure that the
load does not turn or slide along the rope during a lift.

NOTE: The capacity of the basket hitches

is affected by their sling angles.

SINGLE BASKET HITCH

Figure 14

44
The Double Basket Hitch (Figure 15) consists of two single basket hitches placed under the
load. On smooth surfaces the legs will tend to draw together as the load is lifted. To counter this,
brace the hitch against a change in contour, or other reliable means, to prevent the slings from
slipping. You must keep the legs far enough apart to provide balance, but not so far apart that they
create angles below 60 degrees from the horizontal. On smooth surfaces, a Double Wrap Basket
Hitch may be a better choice.

RIGHT To prevent
legs from To prevent
slipping slippage keep
angle 60°
or more.

WRONG Legs will

slide
together.

60° or more

DOUBLE BASKET HITCHES

Figure 15

The Double Wrap Basket Hitch (Figure 16) is a basket hitch wrapped completely around the load
and compressing it rather than merely supporting it, as does the ordinary basket hitch. The double
wrap basket hitch can be used in pairs like the double basket hitch. This method is excellent for
handling loose material, pipe, rod or smooth cylindrical loads because the sling is in full 360°
contact with the load and tends to draw it together.

This hitch
compresses
the load and
prevents it
from slipping
out of the
slings. Pair of Double Wrap Basket Hitches

DOUBLE WRAP BASKET HITCH

Figure 16

45
The Single Choker Hitch (Figure 17) forms a noose in the rope. It does not provide full 360°
contact with the load, however, and therefore should not be used to lift loads difficult to balance
or loosely bundled. Choker hitches are useful for turning loads and for resisting a load that wants
to turn.

Not recommended
when loads are long.

NOTE: Choker hitches are not suited to long loads or loose bundles.

Chokers do not provide full support for loose loads – material can fall out.

SINGLE CHOKER HITCH

Figure 17

46
Using a choker hitch with two legs (Figure 18) provides stability for longer loads. Like the single
choker, this configuration does not completely grip the load. You must lift the load horizontally with
slings of even length to prevent the load from sliding out. You should lift loosely-bundled loads with
a Double Wrap Choker Hitch.

Figure 18

A Double Wrap Choker Hitch (Figure 19) is formed by wrapping the sling completely around the
load and hooking it into the vertical part of the sling. This hitch is in full 360° contact with the load
and tends to draw it tightly together. It can be used either singly on short, easily balanced loads
or in pairs on longer loads.

This hitch
compresses the
load and prevents
it from slipping
out of the sling.

Pair of Double Wrap Chokers

DOUBLE WRAP CHOKER HITCHES

Figure 19

Endless Slings or Grommet Slings (Figure 20) are useful for a variety of applications. Endless
chain slings are manufactured by attaching the ends of a length of chain with a welded or
mechanical link. Endless web slings are sewn. An endless wire rope sling is made from one
continuous strand wrapped onto itself to form a six-strand rope with a strand core. The end is
tucked into the body at the point where the strand was first laid onto itself. These slings can be
used in a number of configurations, as vertical hitches, basket hitches, choker hitches and
combinations of these basic arrangements. They are very flexible but tend to wear more rapidly
than other slings because they are not normally equipped with fittings and thus are deformed when
bent over hooks or choked.

47
NOTE: Ensure that the splice is always clear
of the hooks and load.

Endless or
Grommet
Sling in
Vertical Hitch
Conffiguration

Load

Endless Sling
in Choker
Hitch
Configuration

ENDLESS OR GROMMET SLINGS

Figure 20

Braided Slings (Figure 21) are usually fabricated from six to eight small-diameter ropes braided
together to form a single rope that provides a large bearing surface, tremendous strength, and
flexibility in every direction. They are easy to handle and almost impossible to kink. The braided
sling can be used in all the standard configurations and combinations but is especially useful for
basket hitches where low bearing pressure is desirable or where the bend is extremely sharp.

BRAIDED SLINGS
Figure 21

48
 Sling Angles
The total weight that you can pick up with a set of slings is reduced when the slings are used at
angles (formed the with horizontal). For instance, two slings used to lift 1000 pounds will have a 500-
pound force on each sling (or leg) at a sling angle of 90 degrees (see Figure 22b). The force on each
leg increases as the angle goes down. At 30 degrees the force will be 1000 pounds on each leg!

Keep sling angles greater than 45 degrees whenever possible. Using any sling at an angle lower than
30 degrees is extremely hazardous. In such cases, an error of 5 degrees in estimating the sling can
be very dangerous. The sharp increase in loading at low angles is clearly shown in Figure 22a.

Low sling angles also create large, compressive forces on the load that may cause buckling—
especially in longer flexible loads.

EFFECT OF SLING ANGLE ON SLING LOAD

LOAD PER SLING LEG PER 1000 LBS OF TOTAL LOAD

SLING ANGLE IN DEGREES (TO HORIZONTAL)

Figure 22a

Figure 22b

49
Some load tables list sling angles as low as 15° but the use of any sling at an angle less than 30°
is extremely dangerous. Not only are the loads in each leg high at these low angles but an error in
measurement as little as 5° can affect the load in the sling drastically. For example, the data in
Figure 23 illustrates the effect of a 5° error in angle measurement on the sling load. Notice that
there is a 50% error in the assumed load at the 15° sling angle.

Figure 23

EXAMPLE OF THE EFFECT OF SLING ANGLE

MEASUREMENT ERROR ON LOADS

Assumed Assumed Actual Angle

Actual Load
Sling Load (is 5° Less Than Error %
(Pounds Per Leg)
Angle (Pounds Per Leg) Assumed Angle)

90° 500 85° 502 0.4

75° 518 70° 532 2.8
60° 577 55° 610 5.7
45° 707 40° 778 9.1
30° 1,000 25° 1,183 18.3
15° 1,932 10° 2,880 49.0

50
Centre of Gravity
It is always important to rig the load so that it is stable. The load’s centre of gravity must be directly
under the main hook and below the lowest sling attachment point before the load is lifted (Figure 24).

Unstable
hook is not above
C of G. Load will shift
until C of G is
below hook

Unstable
C of G is above Stable – Hook
lift points. is above center
of gravity.

EFFECT OF CENTRE OF GRAVITY ON LIFT

Figure 24

Centre of gravity is the point around which an object’s weight is evenly balanced. The entire weight
may be considered concentrated at this point. A suspended object will always move until its centre
of gravity is directly below its suspension point. To make a level or stable lift, the crane or hook
block must be directly above this point before the load is lifted. Thus a load which is slung above
and through the centre of gravity will not topple or slide out of the slings (Figure 25).

51
 Load in
this leg
is critical

Unstable Stable
The load can topple because the Attachments are
attachments are below the C of G. above the C of G.

EFFECT OF CENTRE OF GRAVITY ON LIFT

Figure 25

If an object is symmetrical in shape and uniform in composition, its centre of gravity will lie at its
geometric centre. The centre of gravity of an oddly shaped object, however, can be difficult to
locate. One way to estimate its location is to guess where the centre of gravity lies, rig the load
accordingly, signal for a trial lift, and then watch the movement of the suspended load. The centre
of gravity will seek to move, within the constraints of your rigging, toward the line drawn vertically
from the hook to the ground (just like a plumb bob). Adjust the sling suspension for the best
balance and stability.

The centre of gravity always seeks out the lowest point toward the ground. For this reason, the
sling attachment points on your load should be located above the centre of gravity whenever
practical. If the sling attachment points lie below the centre of gravity, your load could flip over or
topple.

When the centre of gravity is closer to one sling leg than to the other, the closest sling leg bears a
greater share of the weight.

When a load tilts after it is lifted, the tension increases in one sling leg and decreases on the other
sling leg. If your load tilts, land the load and rig it again to equalize the load on each leg.

52
Working Load Limits
Knowledge of working load limits (WLLs) is essential to the use of ropes, slings, and rigging
hardware. As indicated in previous sections, the working load limit should be stamped, pressed,
printed, tagged, or otherwise indicated on all rigging equipment.

Field Calculation Formula

The field calculation formula can be used to compute the working load limit of a wire rope in tons
(2,000 pounds). The formula applies to new wire rope of Improved Plow steel and a design factor
of 5.

WLL = DIAMETER x DIAMETER x 8

(where DIAMETER = nominal rope diameter in inches)
OR
WLL = D2 x 8

SINGLE VERTICAL HITCH

Examples:

(a) 1/2 inch diameter rope

WLL = 1/2 x 1/2 x 8 = 2 tons

(b) 5/8 inch diameter rope

WLL = 5/8 x - 5/8 x 8 = 3.125 tons

(c) 1 inch diameter rope

WLL = 1 x 1 x 8 = 8 tons

53
Sling Angle and WLL
In rigging tables, sling capacities are related to set angles of 90 degrees, 60 degrees, 45 degrees,
and 30 degrees. Measuring angles in the field can be difficult; however, you can determine three
of them with readily available tools. When a 90-degree angle is formed at the crane hook, you can
measure this with a square. It forms two 45-degree angles at the load (see Figure 26).

90° angle at hook

corresonds to
45° sling angle

45° SLING ANGLE

Figure 26

A 60-degree angle can also be easily identified (see Figure 27). With a two-leg bridal hitch, a 60-
degree angle is formed when the distance between the attachment points on the load equals the
length of the sling leg.

When L = S,
sling angle is 60°

60° SLING ANGLE

Figure 27

54
Estimating Sling WLLs
Because it is difficult to remember all load, size, and sling angle combinations provided in tables,
some general rules can be used to estimate working load limits for common sling configurations.

Each rule is based on the working load limit of a single vertical hitch of a given size and material
and on the ratio H/L.

H is the vertical distance from the saddle of the hook to the top of the load. L is the distance,
measured along the sling, from the saddle of the hook to the top of the load (Figure 28).

If you cannot measure the entire length of the sling, measure along the sling from the top of the
load to a convenient point and call this distance I. From this point measure down to the load and
call this distance h. The ratio h/l will be the same as the ratio H/L (Figure 28).

The ratio of height (H) to length of the sling (L) provides the reduction in capacity due to the sling
angle. This gives you the value of the reduced capacity of a single vertical hitch. If there are more
than two slings and the load is shared equally by all legs, you can increase this reduced capacity.
The capacity is increased (multiplied) by the number of legs (see 3- and 4-leg hitches on the next
page).

H/L h/l

Figure 28

H/L or h/l will apply equally to the following rules for different sling configurations. The efficiencies
of end fittings must also be considered to determine the capacity of the sling assembly.

REMEMBER: the smaller the sling angle, the lower the working load limit.

55
Bridle Hitches (2-Leg) (Figure 29)
The formula for the WLL of a two-leg bridal hitch is:

WLL (of two-leg hitch) = WLL (of single vertical hitch) x H/L x 2

When sling legs are not of equal

length, use smallest H/L ratio.

DETERMINING CAPACITY OF 2-LEG BRIDLE HITCHES

Figure 29

Bridle Hitches (3- and 4-Leg) (Figures 30 and 31)

The formula for the WLL of a 3-leg bridal hitch is:

WLL (3-leg hitch) = WLL (single vertical hitch) x H/L x 3

The formula for the WLL of a 4-leg bridal hitch is:

WLL (4-leg hitch) = WLL (single vertical hitch) x H/L x 4

Three-leg hitches are less susceptible to unequal distribution since the load can tilt and equalize
the loads in each leg. However, lifting an irregularly shaped, rigid load with a three-leg hitch may
develop unequal loads in the sling legs. To be safe, use the formula for a two-leg bridle hitch
under such circumstances.

When legs are not

of equal length, use
smallest H/L ratio.

DETERMINING CAPACITY OF 3-LEG DETERMINING CAPACITY OF 4-LEG

BRIDLE HITCH BRIDLE HITCH
Figure 30 Figure 31

Note: With 3- and 4-leg bridal hitches, the load can be carried by only two legs while the third
and fourth legs simply balance the load. Therefore, in these situations you should be cautious
and use the formula for a 2-leg configuration.
56
 CAUTION
Three- and four-leg bridal hitches are susceptible to unequal weight distribution, which leads
to only two slings taking the full load while the other leg(s) simply balance the load. It is best to
presume this will happen and set up the slings based on a two-leg bridal hitch.

Remember that the rated capacity of a multi-leg sling is based on the assumption that all legs are
used. If this is not the case, de-rate the sling assembly accordingly and hook all unused legs to
the crane hook so they will not become snagged during the lift.

Single Basket Hitch (Figure 32)

For vertical legs – WLL = WLL (of Single Vertical Hitch) x 2

For inclined legs – WLL = WLL (of Single Vertical Hitch) x H/L x 2

Inclined Legs Vertical Legs

WLL = WLL (of single vertical hitch) x H/L x2 WLL = WLL (of single vertical hitch) x 2

DETERMINING CAPACITY OF SINGLE BASKET HITCH

Figure 32

57
Double Basket Hitch

For vertical legs:

WLL = WLL (of single vertical hitch) x 3

For inclined legs:

WLL = WLL (of single vertical hitch) x H/L x 3

Double Wrap Basket Hitch

Depending on configuration, WLLs are the same
as for the single basket or double basket hitch.

DETERMINING CAPACITY OF DOUBLE BASKET

HITCH WITH INCLINED LEGS

Single Choker Hitch

For choker angles of 45 degrees or more:
WLL = WLL (of single vertical hitch) x 3/4

A choker angle less than 45 degrees

(formed by the choker) is not
recommended due to extreme
loading on the sling. If the angle
does go below 45 degrees, use caution
because it could slip tighter during the
lift. Apply the following formula: When this angle is greater than 45°
WLL = WLL (of single vertical hitch) x 3/4
WLL = WLL (of single vertical hitch) x A/B

When this angle is less than 45°

WLL = WLL (of single vertical hitch) x A/B

DETERMINING CAPACITY
OF SINGLE CHOKER HITCH
Endless and Grommet Slings
Although grommet slings support a load with two legs, their working load limit is usually taken as
1.5 times the working load limit of a single vertical hitch. This reduction allows for capacity lost
because of sharp bends at the hook or shackle.

58
Two-Leg Choker Hitches
With two-leg choker hitches there are two reductions to consider:

1. the angles formed by the choker

2. the angle formed by the sling (bridal hitch).

For bridal-hitch sling angles:

WLL = WLL (of single vertical hitch) x H/L x 2

For choker angles of 45 degrees or more:

WLL = WLL (of single vertical hitch) x 3/4

A choker angle less than 45 degrees (formed by the choker) is not recommended due to
extreme loading of the sling. If the angle does go below 45 degrees, use caution because it can
slip tighter during the lift. Apply the following formula: WLL = WLL (of single vertical hitch) x A/B

When you calculate both reductions together, the WLL is calculated as follows:
WLL = WLL (of single vertical hitch) x H/L x 2 x 3/4.

Or, for small choker angles, the formula is:

WLL = WLL (of single vertical hitch) x H/L x 2 x A/B.

When the choker angle is greater than 45°

WLL = WLL (of single vertical hitch) x 3/4 x H/L x 2

When the choker angle is less than 45°

WLL= WLL (of single vertical hitch) x A/B x H/L x 2

DETERMINING CAPACITY OF DOUBLE CHOKER HITCH

Double Wrap Choker Hitch

Depending on configuration, working load limits are the same as for the Single Choker Hitch or the
Double Choker Hitch.
59
Types of Slings
Wire rope slings should be inspected frequently for broken wires, kinks, abrasion and corrosion.
Inspection procedures and replacement criteria outlined in the session on wire rope apply and
must be followed regardless of sling type or application.

All wire rope slings should be made of improved plow steel with independent wire rope cores to
reduce the risk of crushing. Manufacturers will assist in selecting the rope construction for a given
application.

It is recommended that all eyes in wire rope slings be equipped with thimbles, be formed with
the Flemish Splice and be secured by swaged or pressed mechanical sleeves or fittings. With
the exception of socketed connections, this is the only method that produces an eye as strong as
the rope itself, with reserve strength should the mechanical sleeve or fitting fail or loosen.

The capacity of a wire rope sling can be greatly affected by being bent sharply around pins, hooks
or parts of a load. The wire rope industry uses the term “D/d ratio” to express the severity of bend.
“D” is the diameter of curvature that the rope or sling is subjected to and “d” is the diameter of the
rope.

Wire Rope Slings

The use of wire rope slings for lifting materials
provides several advantages over other types of
sling. While not as strong as chain, it has good
flexibility with minimum weight. Breaking outer wires
warn of failure and allow time to react. Properly
fabricated wire rope slings are very safe for general
construction use.

On smooth surfaces, the basket hitch should be

snubbed against a step or change of contour to
prevent the rope from slipping as load is applied.
The angle between the load and the sling should be
approximately 60 degrees or greater to avoid
slippage. RIGHT

On wooden boxes or crates, the rope will dig into

the wood sufficiently to prevent slippage. On other
rectangular loads, the rope should be protected by WRONG
guards or load protectors at the edges to prevent Legs will slide
kinking. together.

Loads should not be allowed to turn or slide along

the rope during a lift. The sling or the load may
become scuffed or damaged.

To prevent
slippage,
keep angle
60° or more.

60° or more

60
 Working Load Limit (WLL): Tons of 2000 lbs
UNI-LOC® 6-strand Wire Rope Slings
- 6 x 19, 6 x 26, 6 x 25 and 6 x 36 IWRC -
Design Factor = 5
Vertical Choker 2 Sling Bridle, or single Basket Hitch

Weight of
one 10 ft
long Std
Nom. Loop Sling
Rope w/o any
Dia. hardware
Inch 60˚ 45˚ 30˚ approx. lbs
1/4 0.65 0.48 1.1 0.91 0.65 1.6
3/8 1.4 1.1 2.5 2.0 1.4 3.5
1/2 2.5 1.9 4.4 3.6 2.5 6.8
5/8 3.9 2.9 6.8 5.5 3.9 10.9
3/4 5.6 4.1 9.7 7.9 5.6 16.5
7/8 7.6 5.6 13 11 7.6 23.5
1 9.8 7.2 17 14 9.8 32.5
1-1/8 12 9.1 21 17 12 41.0
1-1/4 15 11 26 21 15 53.5
1-3/8 18 13 31 25 18 68.5
1-1/2 21 16 37 30 21 85.0
1-3/4 28 21 49 40 28 130.0
2 37 28 63 52 37 178.0
2-1/4 44 35 77 63 44 243.0
2-1/2 54 42 94 77 54 315.0

For Choker Bridle For Double

Sling, multiply Basket Sling,
values by 3/4. multiply values
by 2.

NOTES: 1) Working Load Limit (WLL) based on UNI-LOC® splice only.

2) Values for Chokers valid only if A is greater than 30˚.
3) Values based on ropes with a tensile strength of EIPS.
4) Shackles and fittings must be sized to the full WLL of sling.
5) WLL Basket Hitch is based on D/d ratio of 25.

Reprinted with permission from UNIROPE Ltd.

61
 Chain Slings
Chain slings are suited to applications requiring flexibility and resistance to abrasion, cutting and
high temperatures.
Alloy steel chain grade 80 is marked with an 8, 80, or 800; grade 100 is marked with a 10, 100, or
1000. Alloy steel chain is the only type which can be used for overhead lifting.
As with all slings and associated hardware, chain slings must have a design factor of 5. In North
America, chain manufacturers usually give working load limits based on a design factor of 3.5 or
4. Always check with manufacturers to determine the design factor on which their working load
limits are based.
If the design factor is less than 5, calculate the working load limit of the chain by multiplying the
catalogue working load limit by the manufacturer’s design factor and dividing by 5.
CATALOGUE WLL x MANUFACTURER’S D.F. = WLL (based on design factor of 5)
5

Example – 1/2” Alloy Steel Chain

Catalogue WLL = 13,000 Ibs.
Design Factor = 3.5
13,000 Ibs x 3.5 = 9,100 Ibs.
5

This chain sling must be de-rated to 9,100 Ibs. for construction applications.
Wherever they bear on sharp edges, chain slings should be padded to prevent links from being
bent and to protect the load. Never tie a knot in a chain sling to shorten the reach. Slings can be
supplied with grab hooks or shortening clutches for such applications.
Inspect chain slings for inner link wear and wear on the outside of the link barrels (Figure 33).
Manufacturers publish tables of allowable wear for various link sizes. Many companies will also
supply wear gauges to indicate when a sling must be retired or links replaced. Gauges or tables
from a particular manufacturer should only be used on that brand of chain since exact dimensions
of a given nominal size can vary from one manufacturer to another.

Wear
Extreme Wear at Bearing Surfaces

Measure the remaining material

and discard if it is less than
allowed by manufacturer.

INSPECT ALL LINKS FOR WEAR AT BEARING SURFACES

Figure 33

A competent worker should check chain slings for nicks and gouges that may cause stress
concentrations and weaken links (Figure 34). If nicks or gouges are deep or large in area, or reduce
link size below allowable wear, remove the chain from service. Any repairs must be done according
to manufacturers’ specifications.

62
 The depth of all chips, cuts, etc., must
not exceed that allowed by manufacturer.

INSPECT ALL LINKS FOR GOUGES, CHIPS AND CUTS

Figure 34
Never use repair links or mechanical coupling links to splice broken lengths of alloy steel chain. They
are much weaker than the chain links. Never use a chain if the links are stretched or do not move freely.

Working Load Limit (WLL): LBS Working Load Limit (WLL): LBS
RIGGER’S CHOICE Chain Slings®
RIGGER’S CHOICE® Chain Slings
- Grade 80 Overhead Lifting Chain - - Grade 80 Overhead Lifting Chain -
Design Factor = 4 Design Factor = 4
Vertical Choker 2 Sling Bridle, or single Basket Hitch 2-leg Adjustable Bridle (ADOS- 3 & 4-leg Bridle Sling (TOS/QOS)

Weight of
one 10ft
long chain
leg with
Nom. Link and Nom.
Chain Hook Chain
Dia. (SOS) Dia.
inch 60˚ 45˚ 30˚ approx lbs inch 60˚ 45˚ 30˚ 60˚ 45˚ 30˚
9/32 3,500 2,800 6,100 4,900 3,500 9.5 9/32 6,100 4,900 3,500 9,100 7,400 5,200
3/8 7,100 5,680 12,300 10,000 7,100 20.0 3/8 12,300 10,000 7,100 18,400 15,100 10,600
1/2 12,000 9,600 20,800 17,000 12,000 36.7 1/2 20,800 17,000 12,000 31,200 25,500 18,000
5/8 18,100 14,480 31,300 25,600 18,100 53.5 5/8 31,300 25,600 18,100 47,000 38,500 27,100
3/4 28,300 22,640 49,000 40,000 28,300 89.0 3/4 49,000 40,000 28,300 73,500 60,000 42,400
For Design Factor 5:1 for Construction sites multiply values by .80. For Design Factor 5:1 for Construction sites multiply values by .80.
Remove alloy lifting chain from service if you detect:
For Choker Bridle For Double Basket
Cuts,
Sling, multiply Hitch multiply above
cracks,
values by 3/4. values by 2. Links
gouged, Links
burned, or which are which are
corroded bent twisted
Wear of more
than 10%
Links which are Check master links and hooks. Hooks must be
stretched or close removed if opened up or twisted. Slings with
NOTES: 1) Values for Chokers valid only if A is greater than 30˚. up and get longer no, or unreadable tags must be discarded. Do
2) Do not use Chain if exposed to temperatures over 260˚ C (500˚ F).
NOT try to repair the sling yourself.
3) Remove chain from service if links are bent or stretched (more than
5%) or hooks are bent open (latches don’t close anymore). NOTES: 1) Do not use Chain if exposed to temperatures over 260˚ C (500˚ F).
4) Do NOT knot chain to shorten it. Use proper chain shorteners. 2) Do NOT knot chain to shorten it. Use proper chain shorteners.
5) Do NOT try to repair the chain yourself. Consult Unirope 3) Do NOT try to repair the chain yourself.
6) In regular intervals have chain inspected, proof-loaded, and re-certified. 4) In regular intervals have chain inspected, proof-loaded, and re-certified.

Reprinted with permission from UNIROPE Ltd.

63
 Synthetic Web Slings
Web slings are available in two materials – nylon and polyester (Dacron). Nylon is resistant to many
alkalis whereas polyester is resistant to many acids. Consult the manufacturer before using web
slings in a chemical environment. Nylon slings are more common but polyester slings are often
recommended where headroom is limited since they stretch only half as much as nylon slings.

Synthetic web slings offer a number of advantages for rigging purposes.

– Their relative softness and width create much less tendency to mar or scratch finely machined,
highly polished or painted surfaces and less tendency to crush fragile objects than fibre rope,
wire rope or chain slings (Figure 35).

SYNTHETIC WEB SLINGS DO NOT DAMAGE OR CRUSH LOADS

Figure 35

– Because of their flexibility, they tend to mold themselves to the shape of the load (Figure 36).

WEB SLINGS MOLD THEMSELVES TO THE LOAD

Figure 36

– They do not rust and thus will not stain ornamental precast concrete or stone.
– They are non-sparking and can be used safely in explosive atmospheres.
– They minimize twisting and spinning during lifting.
– Their light weight permits ease of rigging, their softness precludes hand cuts, and the danger of
harm from a free-swinging sling is minimal.
– They are elastic and stretch under load more than either wire rope or chain and can thus absorb
heavy shocks and cushion loads. In cases where sling stretching must be minimized, a sling of
larger load capacity or a polyester sling should be used.

Synthetic web slings are available in a number of configurations useful in construction.

64
Endless or Grommet Slings – both ends of one piece of webbing lapped and sewn to form a
continuous piece. They can be used as vertical hitches, bridle hitches, in choker arrangements or
as basket hitches. Because load contact points can be shifted with every lift, wear is evenly
distributed and sling life extended (Figure 37).

ENDLESS OR GROMMET SLINGS

Figure 37

Standard Eye-and-Eye – webbing assembled and sewn to form a flat body sling with an eye at
each end and eye openings in the same plane as the sling body. The eyes may be either full web
width or tapered by being folded and sewn narrower than the webbing width (Figure 38).

TAPERED EYES

STANDARD EYE-AND-EYE SLINGS

Figure 38

Twisted Eye – an eye-and-eye with twisted terminations at both ends. The eye openings are at 90°
to the plane of the sling body. This configuration is available with either full-width or tapered eyes
(Figure 39).

65
 TWISTED EYE SLINGS
Figure 39

In place of sewn eyes, web slings are available with metal end fittings. The most common are
triangle and choker hardware. Combination hardware consists of a triangle for one end of the sling
and a triangle/rectangle (choker attachment) for the other end. With this arrangement, choker and
basket as well as straight hitches may be rigged. Such attachments help reduce wear in the sling
eyes and thus lengthen sling life (Figure 40).
Choker Sling

Choker End Fitting

Triangle End Fittings

METAL END FITTINGS

Figure 40

66
Despite their inherent toughness, synthetic web slings can be cut by repeated use around sharp-
cornered objects and abraded by continually hoisting rough-surfaced loads.

Protective devices offered by most sling manufacturers can minimize these effects.

– Buffer strips of leather, nylon, or other materials sewn on the body of the sling protect against
wear (Figure 41A). Leather pads are most resistant to wear and cutting, but are subject to
weathering and deterioration. They are not recommended in lengths over six feet because their
stretch characteristics differ from those of webbing. On the other hand, nylon web wear pads
are more resistant to weathering, oils, grease and most alkalis. Moreover they stretch in the
same ratio as the sling body.
– Edge guards consist of strips of webbing or leather sewn around each edge of the sling (Figure
41B). This is necessary whenever sling edges are subject to damage.
– Sleeve or sliding tube wear pads are available for slings used to handle material with sharp
edges. The pads are positioned on the sling where required, will not move when the sling
stretches, adjust to the load and cover both sides of the sling (Figure 41C).

A – REGULAR. This is the type that is sewn on to give B – EDGE GUARD. A strip of webbing or leather is sewn
fixed protection at expected wear points. They can around each end of the sling. This is necessary for
be sewn anywhere on the sling, at any length on certain applications where the sling edges are
one side or on both sides. subject to damage.

C – SLEEVE. Sometimes called sliding sleeve or tube type wear pads,

these pads are ideal for handling material with sharp edges
because the sleeve doesn’t move when the sling stretches and
adjusts to the load. Sleeves cover both sides of the sling and can
be shifted to points of expected maximum wear.

WEB SLING
Figure 41

– Reinforcing strips sewn into the sling eyes double or triple the eye thickness and greatly
increase sling life and safety.
– Coatings provide added resistance to abrasion and chemicals as well as a better grip on
slippery loads. Coatings can be brightly coloured for safety or load rating.
– Cotton-faced nylon webbing affords protection for hoisting granite and other rough-surfaced
material.

The rated capacity of synthetic web slings is based on the tensile strength of the webbing, a design
factor of 5 and the fabrication efficiency. Fabrication efficiency accounts for loss of strength in the
webbing after it is stitched and otherwise modified during manufacture. Fabrication efficiency is
typically 80 to 85% for single-ply slings but will be lower for multi-ply slings and very wide slings.

Although manufacturers provide tables for bridle and basket configurations, these should be used
with extreme caution. At low sling angles one edge of the web will be overloaded and the sling will
tend to tear (Figure 42).

67
 If the sling angle is too low,
the web can tear here.

EFFECT OF LOW SLING ANGLE ON WEBBING

Figure 42

Slings with aluminum fittings should never be used in acid or alkali environments. Nylon and
polyester slings must not be used at temperatures above 194°F (90°C).

Inspect synthetic web slings regularly. Damage is usually easy to detect. Cuts, holes, tears, frays,
broken stitching, worn eyes and worn or distorted fittings, and burns from acid, caustics or heat
are immediately evident and signal the need for replacement. Do not attempt repairs yourself.

Synthetic web slings must be labelled to

indicate their load rating capacity.

- Twin-Path and Uni-Web Inspection & Handling -

® ®

Tell-Tails must be visible Cover damage

Heat or Acid Burns Abraided web, faded colour NO knots in any sling
(UV degradation)

Cuts
Snags & Punctures
Crushed webbing

Damaged Eye
Sling Handling
Wrong
Right

Right Wrong

Where possible use a Do not

double-wrap hitch. lift on the
sling
Right splice or Right
Right
tag.

Wrong

For complete information call: 905-624-5131

68 Reprinted with permission from UNIROPE Ltd.

Metal Mesh Slings
Metal mesh slings, also known as wire or chain mesh slings, are well adapted for use where loads
are abrasive, hot or tend to cut fabric slings and wire ropes. They resist abrasion and cutting, grip
the load firmly without stretching and can withstand temperatures up to 550° (288°C). They have
smooth, flat bearing surfaces, conform to irregular shapes, do not kink or tangle and resist
corrosion (Figure 43).

CHAIN MESH SLINGS

Figure 43

For handling loads that would damage the mesh, or for handling loads that the mesh would
damage, the slings can be coated with rubber or plastic.

Note that there is no reduction in working load limit for the choker hitch. This is because the hinge
action of the mesh prevents any bending of individual wire spirals. Check the manufacturer’s rating
for the WLL of the specific sling you are using.

69
Fibre Rope Slings
Fibre rope slings are preferred for some applications because they are pliant, grip the load well and
do not mar its surface. They should be used only on light loads, however, and must never be used
on objects that have sharp edges capable of cutting the rope or in applications where the sling will
be exposed to high temperatures, severe abrasion or acids.

The choice of rope type and size will depend on the application, the weight to be lifted and the
sling angle. Before lifting any load with a fibre rope sling, be sure to inspect the sling carefully. Fibre
slings, especially manila, deteriorate far more rapidly than wire rope slings and their actual strength
is very difficult to estimate.

Like other slings, fibre rope slings should be inspected regularly. Look for external wear and
cutting, internal wear between strands, and deterioration of fibres.

Open up the rope by untwisting the strands but take care not to kink them. The inside of the rope
should be as bright and clean as when it was new. Check for broken or loose yarns and strands.
An accumulation of powder-like dust indicates excessive internal wear between strands as the
rope is flexed back and forth during use.

Open Up Rope During Inspections

Proper Method of Opening Up the Rope

70
Rigging Hardware
Know what hardware to use, how to use it, and how its working load limits (WLL) compare with the
rope or chain used with it.

All fittings must be of adequate strength for the application. Only forged alloy steel load-rated hardware
should be used for overhead lifting. Load-rated hardware is stamped with its WLL (Figure 44).

Inspect hardware regularly and before each lift. Telltale signs include:
– wear
– cracks
– severe corrosion
– deformation/bends
– mismatched parts
– obvious damage.

Check for wear

and deformation.

Check for cracks

and twisting. Check for signs
of opening up.

Check for wear

and cracks.
Hook Inspection Areas
Figure 44 Figure 45

Hoisting Hooks
• Should be equipped with safety catches (except for sorting or grab hooks).
• Should be forged alloy steel with WLL stamped or marked on the saddle.
• Should be loaded at the middle of the hook. Applying the load to the tip will load the hook
eccentrically and reduce the safe working load considerably.
• Should be inspected regularly and often. Look for wear, cracks, corrosion, and twisting –
especially at the tip – and check throat for signs of opening up (Figure 45).

71
Safety Tip
Whenever two or more ropes are to be placed over a hook, use a shackle to reduce wear and tear
on thimble eyes.

Wire Rope Clips

Wire rope clips are widely used for making end terminations. Clips are available in two basic
designs: U-bolt and fist grip.

When using U-bolt clips, make sure you have the right type of clip. Forged alloy clips are
recommended. Always make certain that U-bolt clips are attached correctly. The U-section must
be in contact with the dead end of the rope. Tighten and retighten nuts as required by the
manufacturer.

To determine the number of clips and the torque required for specific diameters of rope, refer to
Figure 46. For step-by-step instructions on attaching clips, refer to Figure 47.

Clip Length of
& rope
rope Minimum to turn Required
size No. of back Torque
inch clips in inches in Ft.Lbs
3/16 2 3-3/4 7.5
1/4 2 4-3/4 15
5/16 2 5-1/4 30
3/8 2 6-1/2 45
7/16 3 7 65
1/2 3 11-1/2 65
9/16 3 12 95
5/8 3 12 95
3/4 4 18 130
7/8 4 19 225
1 5 26 225
1-1/8 6 34 225
1-1/4 7 44 360
1-3/8 7 44 360
1-1/2 8 54 360
Reprinted with permission from UNIROPE Ltd.
Figure 46
72
 STEP 1

APPLY FIRST CLIP one base width from

dead end of wire rope. U-Bolt over dead end.
Live end rests in clip saddle. Tighten nuts
evenly to recommended torque.

STEP 2

APPLY SECOND CLIP as close to loop as

possible. U-Bolt over dead end. Turn nuts
firmly but DO NOT TIGHTEN.

STEP 3

APPLY ALL OTHER CLIPS. Space evenly

between first two and 6-7 rope diameters
apart.

STEP 4

Apply
Tension

APPLY TENSION and tighten all nuts to

recommended torque.

STEP 5

Apply
Tension

CHECK NUT TORQUE after rope has been in

operation.

Figure 47
73
Swivels
• Reduce bending loads on rigging attachments by allowing the load to orient itself freely.
• Should be used instead of shackles in situations where the shackle may twist and become
eccentrically loaded.

Shackles
• Available in various types (Figure 49).
• For hoisting, should be manufactured of forged alloy steel.
• Do not replace shackle pins with bolts (Figure 50). Pins are designed and manufactured to
match shackle capacity.
• Check for wear, distortion, and opening up (Figure 51). Check crown regularly for wear. Discard
shackles noticeably worn at the crown.
• Do not use a shackle where it will be pulled or loaded at an angle. This severely reduces its
capacity and opens up the legs (Figure 52).
• Do not use screw pin shackles if the pin can roll under load and unscrew (Figure 53).

74
 Never replace a shackle pin
with a bolt

Screw pin anchor shackle Round pin anchor shackle Safety type anchor shackle

The load will bend the bolt

Screw pin chain shackle Round pin chain shackle Safety type chain shackle

Figure 49 Figure 50

Check for wear

Check for wear and straightness

Check that pin is always seated

Check that shackle is not “opening up”

Figure 51

Packings Hook Don’t use a screw pin shackle if the pin can roll
under load and unscrew.

Poor Practice Good Practice

Never allow shackle to Pack the pin with
be pulled at an angle – washers to centralize If load shifts, sling will
the legs will open up. the shackle. unscrew shackle pin

Figure 52 Figure 53

75
Eye Bolts
• For hoisting, use eye or ring bolts of forged alloy steel.
• Use bolts with shoulders or collars. Shoulderless bolts are fine for vertical loading but can bend
and lose considerable capacity under angle loading (Figure 54). Even with shoulders, eye and
ring bolts lose some capacity when loaded on an angle.
• Make sure that bolts are at right angles to hole, make contact with working
surface, and have nuts property torqued (Figure 55).
• Pack bolts with washers when necessary to ensure firm, uniform contact with
working surface (Figure 55).
• Make sure that tapped holes for screw bolts are deep enough for uniform grip
(Figure 55).
• Apply loads to the plane of the eye, never in the other direction (Figure 55). This
is particularly important with bridle slings, which always develop an angular
pull in eye bolts unless a spreader bar is used.
• Never insert the point of a hook in an eye bolt. Use a shackle instead (Figure 55).
Swivel Eye Bolt
• Do not reeve a sling through a pair of bolts. Attach a separate sling to each bolt.

Correct Incorrect
Shoulderless eye and ring bolts are If shoulderless eye and ring bolts are pulled at an
designed for vertical loads only. angle as shown, they will either bend or break.

Results In

Shoulderless Eye Bolt Shoulderless Ring Bolt

Shoulderless Ring Bolt Shoulderless Eye

Bolt

Figure 54

Working Load Limit (WLL): LBS

- Machinery Eye Bolts (Crosby S-279) -
Design Factor = 5

Size Shim thickness to

inch Vertical 45˚ 90˚ change rotation 90˚ Thread Size
1/4 650 195 163 .0125” 1/4-20
5/16 1,200 360 300 .0139” 5/16-18
3/8 1,550 465 388 .0156” 3/8-16
1/2 2,600 780 650 .0192” 12-13
5/8 5,200 1560 1,300 .0227” 5/8-11
3/4 7,200 2,160 1,800 .0250” 3/4-10
7/8 10,600 3,180 2,650 .0278” 7/8-9
1 13,300 3,990 3,325 .0312” 1-8
1-1/4 21,000 6,300 5,250 .0357” 1.1/4-7
1-1/2 24,000 7,200 6,000 .0417” 1.1/2-6

DO NOT Attach sling

through directly to
reeve ! eye bolt

WRONG
RIGHT

Use Swivel
Right Hoist Rings
Wrong where
possible

76
Reprinted with permission from UNIROPE Ltd.
 Correct for Shoulder Type Eye & Ring Bolts
Providing loads are reduced to account for angular loading.

Incorrect
Pack with
washers to
ensure that
shoulder is
firmly in
contact
with
surface.

Ensure that bolt Ensure that

is tightened tapped hole is
Shoulder must be in
Nut must be into place. deep enough.
full contact with surface.
properly torqued.

Correct Incorrect Orientation –

Orientation – When the load is applied to the
Load is in the eye in this direction, it will bend.
plane of the
eye. LOAD LOAD

RESULT

Correct – Use a shackle

Incorrect

Figure 55

Snatch Blocks
• A single or multi-sheave block that opens on one side so a rope can be slipped
over the sheave rather than threaded through the block (Figure 56).
• Available with hook, shackle, eye, and swivel end fittings.
• Normally used when it’s necessary to change the direction of pull on a line.
Stress on the snatch block varies tremendously with the angle between the lead
and load lines. With both lines parallel, 1000 pounds on the lead line results in
2000 pounds on the block, hook, and anchorage. As the angle between the lines
increases, the stress is reduced (Figure 57).
• To determine the load on block, hook, and anchorage, multiply the pull on the
lead line or the weight of the load being lifted by a suitable factor from the table
in Figure 19.33 and add 10% for sheave friction.

When Open

Figure 56

77
 2000 POUNDS 1840 POUNDS

1000 POUNDS 1000 POUNDS

1410 POUNDS 760 POUNDS

1000 POUNDS

1000 POUNDS

Figure 57

MULTIPLICATION FACTORS FOR

SNATCH BLOCK LOADS

Angle Between Lead Multiplication

and Load Lines Factor

10° 1.99
20° 1.97
30° 1.93
40° 1.87
45° 1.84
50° 1.81
60° 1.73
70° 1.64
80° 1.53
90° 1.41
100° 1.29
110° 1.15
120° 1.00
130° .84
135° .76
140° .68
150° .52
160° .35
170° .17
180° .00

78
Turnbuckles
• Can be supplied with eye end fittings, hook end fittings, jaw end fittings, stub end fittings, and
any combination of these (Figure 58).
• Rated loads are based on the outside diameter of the threaded portion of the end fitting and on
the type of end fitting. Jaw, eye, and stub types are rated equally; hook types are rated lower.
• Should be weldless alloy steel.
• When turnbuckles are exposed to vibration, lock frames to end fittings. This will prevent turning
and loosening. Use wire or manufacturer-supplied lock nuts to prevent turning (Figure 59).
• When tightening a turnbuckle, do not apply, more torque than you would to a bolt of equal size.
• Inspect turnbuckles frequently for cracks in end fittings (especially at the neck of the shank),
deformed end fittings, deformed and bent rods and bodies, cracks and bends around the
internally threaded portion, and signs of thread damage.

Turnbuckle End Fittings

Jaw and Eye Combination

Jaw and Jaw Combination

Hook and Hook Combination

Eye Jaw Stub Hook

(has reduced
capacity)
Hook and Eye Combination

Figure 58

Manufacturer-supplied lock nut Wire

Figure 59

79
Table 8 gives the working load limits for turnbuckles based on the diameter of the shank.
Note how the use of hook end fittings reduces capacity.

Table 8
Turnbuckle Types and Capacities

WLL
Size with WLL Available
& Jaw or with Take-Up
Thread Eye Hook sizes
dia. lbs lbs inch
1/4 500 400 4
5/16 800 700 4-1/2
3/8 1,200 1,000 6
1/2 2,200 1,500 6,9,12
5/8 3,500 2,250 6,9,12
3/4 5,200 3,000 6,9,12,18
7/8 7,200 4,000 12,18
1 10,000 5,000 6,12,18,24
1-1/4 15,200 6,500 12,18,24
1-1/2 21,400 7,500 12,18,24
Reprinted with permission from UNIROPE Ltd.

Figure 60 shows the areas of a turnbuckle that require special attention during inspection.

Check for cracks & bends

Check for thread

damage & bent rods

Check for cracks & bends

Check for thread

damage & bent rods

Check for cracks & bends

Check for thread

damage & bent rods

Check for cracks & deformations

INSPECTION AREAS
Figure 60

80
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.

Spreader Beam Equalizer Beams

Loads in A & B do not change

when beam angle changes.
Loads in C & D will change
if beam angle changes.

81
Hoisting Tips
• Never wrap a wire rope sling completely around a hook. The tight radius will damage the sling.
• Make sure the load is balanced in the hook. Eccentric loading can reduce capacity dangerously
(Figure 61).

Point Loading

CAPACITY IS SEVERELY REDUCED

Figure 61

• Never point-load a hook unless it is designed and rated for such use. Point-loading can cut
capacity by more than half.
• Never wrap the crane hoist rope around the load. Attach the load to the crane hook by slings or
other rigging devices.
• Avoid bending wire rope slings near attached fittings or at eye sections.

82
Section 4

Rigging Tools and Devices

䡲 Jacks (ratchet, hydraulic)

䡲 Blocking and Cribbing
䡲 Rollers
䡲 Inclined Planes
䡲 Lever-Operated Hoists
䡲 Chain Hoists
䡲 Grip-Action Hoists (Tirfors)
䡲 Electric Hoists and Pendant Cranes
䡲 Winches
䡲 Anchorage Points

83
Section 4
Rigging Tools and Devices
The Regulations for Construction Projects require that an inspection and maintenance program be
implemented to ensure that rigging equipment is kept in safe condition. Procedures must ensure
that inspection and maintenance have not only been carried out but have been duly recorded.

Rigging operations often involve the use of various tools and devices such as jacks, rollers, hoists,
and winches. Each has its own unique features, uses, and requirements for safe operation and
maintenance.

The construction regulations also require that the manufacturer’s operating instructions for such
tools and devices be available on site. The rigger must read and follow all of these instructions to
operate and maintain the equipment properly. The rigger must also read any warning information
which may be stamped, printed, tagged, or attached to the rigging device.

This section identifies some of the commonly used rigging tools and devices and explains
procedures for their safe operation and maintenance. For more detailed information, see the Jacks
and Rollers chapter in Specialized Rigging (DS035).

84
Jacks
While there are a great many types of jacks, the ratchet jack and heavy duty hydraulic jack are the
two types most commonly used in construction.

Ratchet jacks are usually limited to capacities under 20 tons because of the physical effort required
to raise such a load. They do, however, have a much longer travel than hydraulic jacks and can
therefore lift loads higher without having to re-block. Most ratchet jacks have a foot lift or “toe” near
the base to lift loads which are close to the ground. Lifts can be made from the “head” or the “toe”
of the jack. These jacks are often called toe jacks or track jacks (Figure 1).

Head

Lifts can be
made from the
head or the toe

Toe

RATCHET JACK
Figure 1

Do not use extensions or “cheaters” on the handles supplied with ratchet jacks. If cheaters are
necessary the jack is overloaded.

Hydraulic jacks are very popular in construction because they are quite compact and can lift very
heavy loads. They are readily available in capacities ranging from a few tons to 100 tons. Some
specialty units have capacities up to 1,000 tons. Lift heights are usually limited to approximately 8
inches or less but some can go as high as 36 inches (Figure 2).

SELF-CONTAINED HYDRAULIC JACK

Figure 2

85
Hydraulic jacks are also available in low profile models that can be positioned under a load close
to the ground (Figure 3). Also known as “button jacks”, these are useful for lifting a load high
enough to get a regular jack in place.

External Pump

Low Profile Jack

“BUTTON” JACK
Figure 3

Like ratchet jacks, hydraulic jacks are available with toe lifts (Figure 4).

HYDRAULIC JACK WITH TOE LIFT

Figure 4

The pumps powering hydraulic jacks may be contained in the jacks or be separate external power
units. Separate units may be hand-operated or electrically powered, but the self-contained pumps
are always hand-operated.

With all types of hydraulic jacks it is critical that no further force be applied after the ram has run
its full travel. The resultant high pressure in the hydraulic fluid can damage the seals and, in the
case of external power units, burst the hoses.

Most external power units are equipped, however, with pressure relief valves. At the factory one
valve will be set at the absolute maximum pressure while another will be adjustable to lower
settings by the user. Make sure you are familiar with the operation of this safety feature.

Most hydraulic jacks can be fitted with a gauge on the housing or at the pump to monitor hydraulic
pressure. When used with a given jack, the gauges can be calibrated to measure the approximate
load on the unit.

86
Hoses connecting pumps to jacks require careful attention. Make sure they are free of kinks and
cracks. Check the couplings, especially at the crimp. This area is prone to cracking and is often the
weak link in the hose assembly. Threads should also be checked for damage, wear, cross-threading
and tightness. Remember that these hoses have to withstand pressures up to 10,000 psi.

Don’t use hoses that are unnecessarily long. Shorter hoses will leave the area less congested and
reduce the chance of accidental damage.

The handles on jacks or hand-operated pump units are designed so that the rated capacity and
pressure can be obtained with little physical effort. Don’t use extensions or “cheaters” on the
handles. Again, if the load can’t be raised with the handle supplied the jack is overloaded.

Jacks should only be used in a true vertical position for lifting. Otherwise side-loading can cause
the piston to rub against the housing. If this happens, the piston will be scored and allow fluid to
leak at the seal which may cause the jack to slip.

Be extremely careful when using hydraulic jacks in welding areas or around corrosive chemicals.
Sparks or acids can cause pitting on the ram or damage hoses.

Hydraulic jacks are generally not equipped with check valves. But check valves can be installed in
the hoses of an external pump and are recommended. Alternatively, some hydraulic jacks have
retaining nuts that can be screwed against the housing to hold the load for a short time.

Jacks should never be used for long-term support of a load. Blocking is much more stable and
safe. Whenever possible, the load should be progressively blocked as jacking proceeds. This will
allow for the unexpected.

Always jack loads one end at a time. Never jack loads one side at a time as this will be far less
stable than jacking the ends.

If it is necessary to work or even reach under a load on jacks, place safety blocking under the load
as a precaution.

Make sure timbers used for blocking or cribbing are long enough to distribute the load over a large
enough area and provide sufficient stability. Crib height should not exceed the length of timbers
used.

All jacks should be thoroughly inspected periodically, depending on how they are used. For regular
use at one location they should be inspected every six months or more frequently if the lifts
approach capacity. Jacks sent out for special jobs should be inspected when received and when
returned. Jacks subjected to high loads or shock should be inspected immediately.

Because jack bases are relatively small, care must be taken to ensure that the floor or ground can
withstand the high pressures often associated with jacking operations. Blocking or matting under
the jacks will distribute the load over a greater area and reduce bearing pressure.

87
Jacks – Inspection

Whether ratchet or hydraulic, all jacks should be inspected before each shift or use. Check for:

• improper engagement or extreme wear of pawl and rack

• cracked or broken rack teeth
• cracked or damaged plunger
• leaking hydraulic fluid
• scored or damaged plunger
• swivel heads and caps that don’t function properly
• damaged or improperly assembled accessory equipment

Remember: When using jacks, always try to block as you go. Never use jacks for long-term
support. Block properly instead.

Blocking and Cribbing

Blocking or cribbing must

• be sufficient to support load

• be set on firm, level ground or floor
• be close together
Correct
• be dry and free of grease
• be stacked no higher than the length of the timbers used
• follow the jacking process
• distribute load over enough area to provide stability.
Note: In some cases, solid blocking may be required.

Incorrect

88
Rollers

Rollers can be used for moving loads horizontally or on slight inclines, provided the surface is firm
and even. Rollers may be aluminum or steel round stock, heavy steel pipe, or a manufactured
caster unit (Figure 5).

CASTER-TYPE ROLLER
Figure 5

Cylinder rollers are useful for short distances or where the load will have to negotiate corners. The
rollers can be placed on angles to swing the ends of the load, allowing turns in tight areas (Figure 6).

CYLINDER-TYPE ROLLERS
Figure 6

Cylinder rollers should be round, true and smooth to minimize the force required to move the load.
Caster rollers can be supplied in a number of configurations for flat surfaces, tracks, I-beams or
channels. They create very little friction and allow heavy loads to be moved with little force. In fact,
the rigger may sometimes require more friction to provide an extra measure of control.

The most important aspect in rolling is control of the load. Make sure that all equipment including
slings and hardware is sufficient to handle the loads that will be developed at each stage of the
operation. Always attach a second means of restraint such as a tirfor or winch to the load to allow
for the unexpected. The possibility of shock loads should be considered when sizing winches or
tirfors for back-up protection.

Check the condition of floors or ground before using rollers. Bearing pressure can be reduced by
using more rollers and large steel or aluminum plate to distribute the load. Make sure the joints in
the plates or skids are staggered. It is often necessary to assess the structure supporting floors.
Temporary shoring may be necessary.

89
Inclined Planes
The method used to calculate the required pull up an incline is only approximate. Though widely
used because of its simplicity, the method yields values higher than the actual force required. The
formula is more accurate for slight inclines (1:5) than steep inclines (1:1). Table 1 shows the
difference between the actual pull required and the pull calculated with friction of 5%.

TABLE 1

Actual Force versus Force Calculated by Simplified Method with 5% Friction

Simplified Method F = .250W

Actual Force F = .245W
Error: 2%

Simplified Method F = .383W

Actual Force F = .364W
Error: 5%

Simplified Method F = .550W

Actual Force F = .492W
Error: 12%

Simplified Method F = 1.05W

Actual Force F = .742W
Error: 42%

For most applications the simplified method is adequate because the value used for friction is itself
only approximate.

Formula (5% Friction)

F = W x H/L + .05W
where
F = Required Force
H = Height
L = Length
W = Weight of Load

Table 2 lists some examples of approximate coefficients of friction. Note that some of the
combinations of materials have a considerable range of values.

TABLE 2

Examples of Friction Coefficients

Steel on Steel 40-60%

Leather on Metal 60%
Wood on Stone 40%
Iron on Stone 30-70%
Grease Plates 15%
Load on Wheels or Rollers 2-5%

90
Lever-Operated Hoists or Come-Alongs
Come-alongs are a very portable means of lifting or pulling loads short distances. They can be
used vertically, horizontally or on an angle. Otherwise all points covered in the section on chain
hoists apply equally to come-alongs.

A come-along that requires the use of a cheater or the help of another worker to move a load is
inadequate for the job. Use a come-along with a larger capacity.

Lever-Operated Hoist – Safety Precautions

• Inspect for defects.
• Do not use cheater on hoist handle.
• Do not overload. Working load limit (WLL) should be marked on device.
• Do not apply the load to the tip of the hook.
• Do not use the hoist chain as a sling or choker.
• Make sure of your footing before operating the hoist.
• Do not leave the suspended load unattended.
• Keep hoist chain straight.
• Stand clear of load and pulling path of hoist chain.
• Keep upper and lower hooks in a straight line so that the frame is free to swivel.
• Do not use a hoist with a twisted, kinked, damaged, or worn chain.
• Ensure that anchorage and structure will support the load.

CHAIN HOISTS
Chain hoists are useful because the load can be stopped and kept stationary at any point. Because
of their slow rate of travel, chain hoists also allow precise vertical placement.

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
against an object while under load it can be damaged or broken (Figure 10).

Always make sure that the hoist is hanging freely.

91
Before using the hoist, inspect the chain for nicks, gouges, twists, and wear. Check the chain guide
for wear. Hooks should be measured for signs of opening up. Ensure that the hooks swivel freely
and are equipped with safety catches. If the hoist has been subjected to shock loads or dropped,
it should be inspected thoroughly before being put back in service. Check the load brake by raising
the load a couple of inches off the ground and watching for creep.

If the hoist chain requires replacement, follow the manufacturer’s recommendations. Different
manufacturers use different pitches for their load chain. Chain intended for one brand of hoist will not
mesh properly with the lift wheel of another brand and the hoist will not operate properly, if at all.

The load chain on chain hoists is case-hardened to reduce surface wear and is unsuitable for any
other use. Load chain will stretch 3% before failing, whereas Grade 8 alloy chain will stretch at least
15%. Load chains are too brittle for any other application. Any load chain removed from a hoist
should be destroyed by cutting it into short pieces. Never try to repair a load chain yourself.
Welding will destroy the heat treatment of the chain entirely.

Figure 10

WRONG RIGHT

Chain Hoist – Safety Precautions

• Inspect for wear and damage regularly.
• Do not overload.
• Do not leave a suspended load unattended.
• Do not stand under the load.
• Do not use the hoist chain as a sling or choker.
• Do not apply the load to the tip of the hook.
• Avoid hoisting on angles.
• Chain hoists must be used in the vertical position.
• Only one operator should pull on a single hand chain at one time.
• Ensure that load chain is properly seated in wheels or sprockets before lifting.
• Ensure that anchorage and structure will support the load.
• Maintain the chain hoist according to manufacturer’s specifications.

92
Grip Action Hoists or Tirfors
Grip-action hoists, commonly known by the trade name Tirfor, are useful for long lifts or pulls since
they act on a continuous length of wire rope. Like the come-along, they can be used in any
orientation. The tirfor can draw rope through the unit, as a come-along draws chain, or pull itself
along a fixed rope, as on a swingstage (Figure 11).

TIRFOR APPLICATIONS
Figure 11

Tirfors are available with capacities ranging from 3/4 to 31⁄2 tons. The rope can be reeved through
a block system to gain mechanical advantage and increase the capacity of the unit.

Tirfors are operated by two levers – one for forward motion, the other for reverse. The levers
operate two jaws which alternately grip and draw the rope through the unit. Figure 12 illustrates
the action of the jaws on the rope. A third lever releases both jaws to allow rope to be installed,
tensioned, or disengaged.

THE TIRFOR PRINCIPLE

Figure 12

93
Tirfors can be fitted with hydraulic rams to operate the levers. Up to four units can be operated
simultaneously from a single hydraulic power supply (Figure 13).

HYDRAULICALLY ACTUATED TIRFORS WITH COMMON POWER SOURCE

Figure 13

Another type of grip-action hoist uses discs to clamp and drive the rope in a continuous motion
(Figure 14). These are available with electric, air, or hydraulic motors. Disc type hoists provide
greater rope speed but less capacity than the jaw type.

DISC-TYPE HOIST OR PULLER

Figure 14

Tirfor ropes are specifically designed for the clamping and pulling forces applied to them. The
ropes are galvanized and unlubricated and have very tight diameter tolerance. No other rope
should ever be used on tirfors.
Handle tirfor rope carefully to ensure that it does not kink. Kinked rope will jam in the mechanism
and prevent the rope from passing through the hoist. Ropes must be kept free from dirt and oil to
ensure smooth, safe operation.
Like chain falls and come-alongs tirfors should be tested under load to ensure that the unit
functions properly in both directions and that there is no slippage.

94
Electric Wire Rope Hoists, Electric Chain Hoists, Pendant Cranes
Electric wire rope and electric chain hoists may be suspended from a fixed point or a trolley. The
trolley may be motorized but very often the hoist is moved by tugging gently on the pendant. These
units can only move along a fixed straight line (beam).
Pendant cranes, on the other hand, trolley along a bridge (east-west) which travels on rails (north-
south). Pendant cranes have greater capacity than the other hoists and usually have two or more
parts of line.
Apart from these differences, the devices are quite similar in operating procedures and
precautions. Hoist operators must adhere to the following points.
• Know and never exceed the working load limit of the hoisting equipment.
• Ensure that controls work properly without excessive play, delay or effort.
• Check pendant control cable for cuts, kinking, or signs of wear.
• Check hoist cables for fraying, kinking, crushing, and twisting between the cable and the drum.
• Look at the hoist drum for proper alignment and stacking of the cable.
• Inspect the hook for cracks, bending, or distortion, and the safety latch for proper operation.
• Don’t try to lengthen or repair the load chain or rope.
• Read and follow manufacturer’s instructions and all instructions and warnings on the hoist.
• Position the hoist directly over the load.
• After the hook is placed in the lifting ring, apply slight pressure to the hoist to ensure that the
lifting ring is seated in the bottom of the hook and that the hook is properly aligned.
• Between lifts, check whether the rope is properly seated on the drum.
• Ensure that the intended path of travel is clear of people and obstructions and that the intended
destination is ready to receive the load.
• Check brakes for excessive drift.
• Ensure proper clearance for movement.
• Position yourself on the pendant side of the hoist to get maximum clearance from the load and
to prevent entanglement of cables.
• Avoid sudden starts, stops, or reverses.
• Raise the load only high enough to avoid obstructions.
• Do not hoist loads over workers; wait until the area is vacated.
• Be alert for any variation in hoist operation and any possible malfunction.
• Do not leave a load suspended in the air. If a short delay is unavoidable, lock the controls.
• Do not allow unqualified personnel to operate hoists.
• Never operate hoist to extreme limits of chain or rope.
• Avoid sharp contact between two hoists, between hoist and end post, and between hooks and
hoist body.
• Never use the hoist rope or chain as a sling.
• Never use chain or rope as a ground for welding or touch a live welding electrode to the chain
or rope.
• Avoid swinging the load or hook when travelling the hoist.
• Pull in a straight line so that neither hoist body, load chain nor rope is angled around anything.
Some hoists are equipped with limit switches. Generally these devices stop the wind automatically
at its maximum allowable up position, down position and travel limits (if rail-mounted). Check limit
switches daily for correct operation.

95
Whenever the operator does not have a clear view of the load and its intended path of travel, a
signaller must direct operations. Signals for pendant cranes differ from those for mobile and tower
cranes since machine movements are different (Figure 15). Make sure that everyone involved
knows the signals required for pendant cranes.

STOP.
Arm extended, palm DOG EVERYTHING.
down, move hand Clasp hands in front
right and left. of body.

MOVE SLOWLY.
Use one hand to give
any motion signal and
place other hand
motionless in front of HOIST.
hand, giving the With forearm vertical,
motion signal. (HOIST forefinger pointing up,
SLOWLY SHOWN AS move hand in small
EXAMPLE). horizontal circles.

MULTIPLE
TROLLEYS.
LOWER. Hold up one finger for
With arm extended block marked “1”,
downward, fore–finger and two fingers for
pointing down, move block marked “2”.
hand in small Regular signals
horizontal circles. follow.

TRAVEL.
Arm extended TROLLEY TRAVEL.
forward, hands open Palm up, fingers
and slightly raised, closed, thumb
making pushing pointing in direction
motion in direction of of motion, jerk hand
travel. horizontally.

SIGNALS FOR PENDANT CRANES

Figure 15

96
Winches
Base-mounted winches, or tuggers, are a compact, versatile tool for many hoisting and rigging
operations (for more detailed information, see the Tuggers chapter in Specialized Rigging—DS035).
They are particularly useful in areas not accessible to mobile cranes or where there is not enough
headroom for a crane to operate. Figure 16 shows a tugger and snatch block arrangement for
hoisting. Make sure that the rope leaves the drum at a downward angle and that the loose end is
securely anchored.

Figure 16

The forces on snatch blocks and their anchorage points depend on the angle by which the direction
of pull is changed. The diagrams below indicate how snatch block loads vary with rope angle.

2000 POUNDS 1840 POUNDS

1000 POUNDS 1000 POUNDS

1410 POUNDS 760 POUNDS

1000 POUNDS

1000 POUNDS

Wire rope used on tuggers should have an independent wire rope core to resist crushing as it is
compressed by successive layers of rope on the drum.

97
Anchorage Points
Hoists, winches, tirfors, and other rigging devices require secure anchorage points. Anchors may
be overhead, in the floor, or at lateral points in walls or other structures. The arrangement may
involve columns, beams, beam clamps, welded lugs, slings, or block and tackle. Whatever the
method, riggers must be certain of the loads involved and the anchorage required.

Load on Structure
The following examples illustrate how to calculate the load on the structure in two typical
applications.

Lead Line Load = Load + Parts of Line at Load

Lead Line Load A = 500 ÷ 1

= 500 Ib

Lead Line Load B = 6000 ÷ 4

= 1500 lb

Load on Structure = Load + Lead Line Load

Load on Structure A = 500 + 500

= 1000 Ib

Load on Structure B = 6000 + 1500

= 7500 Ib

98
Columns
Columns are generally not designed to withstand significant lateral forces. Anchorage points
should be placed at the base, near a connection to a beam or other lateral support (Figure 1).
Because the member is already in compression, the effect of a small deflection is amplified and the
column could buckle.

ANCHOR PLACEMENT ON COLUMNS

Figure 1

Beams
Load beams near column or other vertical support points to minimize bending (Figure 2). If the
beam is an I section, it may be necessary to weld stiffeners to the web to withstand the additional
shear force applied (Figure 3).

ANCHOR PLACEMENT ON BEAMS WEB STIFFENER

Figure 2 Figure 3

99
Beam Clamps
Beam clamps provide a very secure anchorage point if used correctly. They are commonly
available with capacities up to 12 tons and have various jaw widths. Figure 5 shows different types.

The jaws are usually designed for a range of flange widths. For example, one clamp might fit
flanges 41⁄2” to 9” wide. Clamps should never be used on flanges outside the range specified as
they will not afford sufficient grip on the member.

BEAM CLAMPS
Figure 5

Most beam clamps are designed for use at 90° to the flange. For applications requiring an angle
loading, make sure that the clamp is designed for it and that the beam can withstand it (Figure 6).

LOAD LOAD

IN LINE LOADING
Figure 6

Be particularly careful that the load does not deform the flange. This is most likely to occur with
light sections where the flange is wide and thin.

Beam clamps should be centred on the flange and properly seated.

Manufacturers are required to mark beam clamps with working load limits. But the ratings apply
only to the clamps. The capacity of the beam must be evaluated separately.

100
Slings
Slings are a common method of anchoring equipment to a structure. The double wrap basket hitch
is the preferred method since the load in the sling is shared on two legs and the double wrap
distributes the load on the member. It is also less prone to slippage than a single choker or single
basket hitch. Make sure that the sling is long enough to avoid sharp angles in the legs (Figure 7).

Avoid sharp angles here

LASHING AROUND COLUMN OR BEAM

Figure 7

The use of softeners will protect the member and the sling from damage and increase the radius
of bending in the sling. Figure 8 shows how strength diminishes as wire rope is bent around smaller
and smaller diameters.

STRENGTH EFFICIENCY OF WIRE ROPE

WHEN BENT OVER PINS OR SHEAVES OF VARIOUS SIZES
Figure 8

101
Welded Lugs
Lugs welded to a beam or column must be compatible with the member in metallic composition.
The appropriate welding rod must also be used. The lug should be welded on the centre line of the
flange, in line with the web (Figure 9). Keep loading in line with the lug. Avoid side loading.

LUG PLACEMENT ON I SECTION

Figure 9

Whatever the method of attachment, it is important to realize that the structure is usually not
designed for the additional loads applied. The only way to be sure is through evaluation by a
structural engineer.

102
Section 5

Introduction to Crane Operations

䡲 Responsibilities
䡲 Basic Types and Configurations
䡲 Hazards in Crane Operating Areas
䡲 Working near Powerlines
䡲 Factors Affecting Crane Capacity
䡲 Setup Summary
䡲 Machine Selection
䡲 Signalling

103
Section 5
Introduction to Crane Operations

Crane operation carries with it a greater potential for disaster than nearly any other activity on a
construction project. Crane accidents are often the most costly construction accidents when
measured either in lives or in dollars. All personnel involved in crane operations must understand
their jobs, their responsibilities, and their part in the overall safety of each lift.

Preparation begins with a clear definition of responsibilities. No single set of guidelines can cover
every detail of the many different types of crane operations. But this section spells out primary
responsibilities for the major parties involved – owners, operators, site supervision, and workers.

Responsibilities entail knowledge. Riggers must be trained and experienced. They must know how to:

• establish weights
• judge distances, heights, and clearances
• select tackle and hardware suitable to the load
• rig the load safely.

Signallers must be competent and capable of directing the crane and load to ensure safe, efficient
operation. Knowledge of the hand signals for hoisting is a must, as it is for operators.

The crane operator is generally responsible for the safety of the operation as soon as the load is
lifted clear of the ground. Whenever there is reasonable cause to believe that the lift may be
dangerous or unsafe, the operator must refuse to proceed until the concern has been reported to
the supervisor, any hazard has been corrected, and safe conditions have been confirmed.

This section includes information of use to riggers, operators, and others involved either directly
or indirectly in crane operations. The information covers major responsibilities, hazards and
safeguards in crane operating areas, factors that affect crane capacity, pinch points and other
hazards around equipment, considerations for safe setup, requirements for providing signallers,
and the international hand signals for hoisting.

104
Responsibilities

Crane Owner
The crane owner must ensure that
• safe, suitable equipment is provided to meet the requirements of the job
• operators are capable and aware of their responsibilities
• maintenance, repair, transport, assembly, and other personnel are trained and experienced to
handle their specific jobs
• training and upgrading are provided for all personnel
• responsibilities and authority are clearly designated for each crew
• a thorough equipment maintenance and inspection program is in operation, including logbooks
and other required documentation
• client and site supervision are capable and aware of their responsibilities
• equipment is maintained and inspected in accordance with manufacturer’s requirements and
applicable regulations.

Operator
The operator is generally responsible for the safety of the crane operation as soon as the load is
lifted. Operators must know:

• the particular model of crane they operate, its characteristics, functions, and limitations
• the information in the crane’s operating manual
• the crane’s load chart, including all notes and warnings, and how to calculate or determine the
crane’s actual net capacity in every possible configuration
• proper inspection and maintenance procedures to be followed in accordance with the guidelines
of manufacturer and owner
• any site conditions that may affect crane operation, including the presence of overhead
powerlines
• basic load rigging procedures.

In addition, the Operator must:

• inform the owner, in writing, of any problems with the machine, preferably in the machine’s
logbook
• record in the logbook all inspection, maintenance, and work done on the crane in the field
• check that the site is properly prepared for crane operation
• review plans and requirements with site supervision
• find out the load and rigging weight and where the load is to be placed.

105
[Although operators are NOT responsible for determining load weights, they become responsible
if they do so or if they lift the load without checking the weight with site supervision.]

• determine the number of parts of hoist line required

• check the load chart to ensure that the crane has enough net capacity for each planned lift
• select the best boom, jib, and crane configuration to suit load, site, and lift conditions
• assume responsibility for assembling, setting up, and rigging the crane properly
• follow the manufacturer’s operating instructions in accordance with the load chart
• consider all factors that may reduce crane capacity and adjust the load weight accordingly
• maintain communication with signallers
• ensure that the oiler is in a safe place during operation
• operate in a smooth, controlled, and safe manner
• shut down and secure the machine properly when leaving it unattended.

Site Supervision
Site supervision (foreman, rigger foreman, lead hand of the trade involved, etc.) has overall
responsibility for the lift and must therefore plan all phases of the operation. Specifically, site
supervisors must:

• supervise all work involving the crane

• determine the correct load weight and radius and inform the operator
• ensure that the rigging crew is experienced and capable of establishing weights; judging
distances, heights, and clearances; selecting tackle and lifting gear suitable to the loads; rigging
the load safely and securely
• supervise the rigging crew
• ensure that the load is properly rigged
• ensure that signallers are capable of directing the crane and load, including use of the
international hand signals where other forms of communication are not possible
• designate signallers and identify them to the operator
• ensure the safety of the rigging crew and other personnel affected by crane operations
• keep the public and all non-essential personnel clear of the crane during operation
• control the movements of all personnel in the area affected by the lift
• ensure all required precautions when the lift is near powerlines
• ensure that all personnel involved in the operation understand their jobs, responsibilities, and
their role in the overall safety of each lift.

106
Basic Types and Configurations

The evolution of the mobile crane has led to many types and designs to satisfy both the general
as well as the specific needs of construction and industrial operations. This manual is concerned
with mobile cranes used for construction purposes as well as industrial applications.

The basic operational characteristics of all mobile cranes are essentially the same. They include:

• Adjustable boom lengths

• Adjustable boom angles
• Ability to lift and lower loads
• Ability to swing loads
• Ability to travel about the job site under their own power.

Within the broad category of mobile cranes there have evolved the following basic types and
configurations:

• Boom Trucks
• Industrial Cranes
• Carrier-Mounted Lattice Boom Cranes
• Crawler-Mounted Lattice Boom Cranes
• Carrier-Mounted Telescopic Boom Cranes
• Crawler-Mounted Telescopic Boom Cranes
• Rough Terrain Cranes
• Mobile Tower Cranes
• Heavy Lift Mobile Cranes.

107
Boom Trucks

Unlike all other mobiles, these cranes are

mounted on carriers not designed solely for
crane service. They are mounted on a
commercial truck chassis that has been
specially strengthened to accept the crane.
They are, however, a type of mobile crane
with respectable capacity and boom length.

Included in this basic type of machine are

two common configurations.
Telescoping
Boom
Section

TELESCOPING BOOM
Boom sections are usually Base or Heel Section
telescoped either manually
or hydraulically.

Boom Elevating or Lift Cylinder

Swing Circle

Turret or Pedestal

Commercial Truck Chassis

Rear Stabilizers Front Stabilizers

Knuckle Boom or Articulating Boom

KNUCKLE BOOM
The boom articulates (folds) under hydraulic Hydraulic Cylinders
pressure and may or may not be equipped
with a powered drum and wire rope.
Swing Circle
Turret or Pedestal

Commercial Truck Chassis

Stabilizers

108
Industrial Cranes

These cranes are primarily intended for operation

in industrial locations where working surfaces are
significantly better than those found on most
construction sites.

Although these cranes will not be analyzed

specifically, their characteristics are basically
Telescopic Boom Sections
identical to those of telescopic boom mobiles,
which are covered in detail.

Base (Heel) Section

Boom
Elevating or Partial or 360° Swing
Lift Cylinders

Outrigger Rear Steer or Front

Equipped and Rear Steer

Telescopic Boom PICK AND CARRY

Sections

Telescopic Boom Sections

These cranes have

low centres of
gravity to permit
operation in narrow
Base (Heel) Section aisles or runways
without riggings. Base (Heel) Section

Fixed Boom
Partial or 360° Swing

Carry Deck
Carry Deck

Rear Steer or Front

Outrigger Rear Steer or Front and Rear Steer
Equipped and Rear Steer

CARRY DECK – ROTATING BOOM CARRY DECK – FIXED BOOM

109
Carrier-Mounted Lattice Boom Cranes

This “truck type” carrier must not be

confused with the ordinary commercial
truck chassis. It is specially designed for
crane service and the heavy loads these
cranes are required to withstand.

Carrier-mounted cranes are also

commonly referred to as “Truck Cranes”,
“Conventional Cranes”, “Friction Cranes”,
Boom Head or Tip Sheaves
“Mobile Cranes”, etc.
Auxiliary or
Whip Line
Boom Head or Tip Section
Headache Ball
or Overhaul Ball

Main Hoist Line or Deflector (Idler) Sheaves

Main Falls

Load Block or
Main Hook
Block

Auxiliary Hoist Line

The upperworks (superstructure)
Main Hoist Line of the crane refers to the crane
structure that lies above the
swing circle. It does not include
the carrier.

Lattice Boom Inserts

or Sections Boom Pendants (Stays)

Bridle
Live Mast

Boom Hoist Reeving

Boom Stops or Backstops
Heel, Base, Butt or Boom Foot Section
Counterweight
Swing Circle, Ring Gear, Roller Path or Turntable Carrier

Center Pin, Center of Rotation, Axis of Rotation

Mid-Point (Intermediate) Suspension

(Necessary when raising very
long booms off the ground.
They prevent the boom from
sagging excessively.) Jib Mast, Strut or Gantry
Jib Backstay Pendants
Bail Boom Pendants
Equalizer or Bridle Jib Forestay Pendants

Jib

Backhitch Gantry

Auxiliary, Jib or Whip Line

110
Carrier-Mounted Lattice Boom Cranes (continued)

Bridle

Live Mast

Boom Hoist Reeving

Boom Stops

Machine Deck (houses hoist machinery)

The entire rotating structure of

the crane above the swing
circle is called the upperworks,
Boom Foot Pins upper, superstructure or
& Lugs revolving superstructure.

Outrigger
Cylinder Boom Pendants
(Jack, Ram)

Equalizer,
Bridle, Outer Bail, or
Outrigger Pad, Floating Harness
Front Bumper Outrigger Float, Pontoon
Counterweight Beam

Inner Bail, Bridle

or Harness

Gantry or “A” Frame

Backhitch

Lattice Members

Outrigger Jack

Lattices or
Lacings
Main Chord Outrigger Box
Diagonal
The square frame at Pin Connection Lug
each end of a boom
insert is commonly
referred to as the
picture frame.

111
Crawler-Mounted Lattice Boom Cranes

Except for their base and method of load

rating, the upperworks of these machines
are identical to the carrier-mounted units.

Jib Tip Sheave

Jib or Whip Line

Jib Hook & Headache

Ball or Overhaul Ball
Jib Forestay Pendant or Forestay
Jib Tip Section

Jiib Mid Section

Jib Mast (Gantry)
Deflector (Idler) Sheave Jib Heel Section

Boom Tip Sheaves (Head Sheaves)

Jib Backstay Pendant or Backstay

Main Hoist Line

Boom Pendants

Main Block or Main Hook

Equalizer or Outer Bail

Boom Hoist Reeving

Inner Bail

Backhitch
Upperworks or superstructure
Gantry refers to the entire crane
structure above the
swing circle.
Boom Hoist Rope

Counterweight Ring Gear, Turntable, Swing Circle

Machine Deck

Illustration shows a unit

with traction shaft and
chain drive but hydrostatic
track drive systems are
also available.

Carbody, Truck Frame Lower Frame, Axle Track Carrier Roller

Track Shoe
Ring Gear
Drive Chain

Idler Roller

Tread Sprocket
Track Rollers, Traction Shaft Side Frame or Drive Sprocket
Support Rollers

112
Carrier-Mounted Telescopic Boom Cranes

These machines are also mounted on specially

designed carriers. They can be equipped with
a variety of jibs and boom extensions which
can be stowed on or under the heel section
of the main boom.

Main Boom Tip (Head)

#3 Power Telescoping
Section or Planed Section

Main Hoist Line

“A” Frame Jib

Jib Forestay Pendant

#2 Power Telescoping Section

Jib Mast or Gantry

Whip Line or Main Hook or Hook Block
Jib Line or
Boom Extension Tip
Auxiliary
or Head Sheave
Hoist Line
Jib Backstay Pendant
#1 Power Telescoping Section
Jib Hook &
Headache Ball
Removable Boom Extension

Main Boom Tip Sheave Main Boom Tip

Jib Line (Whip Line)

Main Hoist Lines
Heel, Base, or
Foot Section
Main Hoist Line
Main Hoist
Main Hook or Hook Block
Boom Hoist or Lift Cylinders Auxiliary Hoist
Counterweight
Upperworks
Carrier

Center Pin, Center of Rotation, Axis of Rotation Boom Foot Pins, Hinge Pins
Telescopic Jib

Boom Extension Tip Sheave

“A” Frame Jib

Jib Pendant
Boom Extension
Auxiliary or Whip Line

Deflection Sheave
Auxiliary Hook &
Headache Ball

113
Carrier-Mounted Telescopic Boom Cranes (continued)

Luffing jib can be raised or lowered independently

of the boom. In this case the crane’s auxiliary
winch is used as the jib hoist.

Jib Tip Section

Lattice Jib

Jib Heel or Base Section

Jib Forestay Pendant

Jib Mast or Gantry

Jib Backstay Pendant

114
Carrier-Mounted Telescopic Boom Cranes (continued)

Carrier-mounted telescopic boom cranes are

subdivided by the type of head section (boom
tip section) they are equipped with.

On full power
hydraulic booms
the end section
(tip or fly) extends
through its full
range as the
whole boom
extends.
FULL POWER BOOMS

PINNED BOOMS

…or fully extended

at all times. Its
length cannot be
On “pinned booms”, varied with the
the end (tip or fly) total boom length.
section is either fully
retracted at all times
(regardless of main
boom length)…

These sections
extend and retract
under power through
their full range.

115
Crawler-Mounted Telescopic Boom Cranes

The upperworks of these cranes are identical

to the carrier-mounted telescopic boom units.
Their bases and the method used to load rate
them differ, however.

Auxiliary Hoist Line

Boom Extension

Main Hoist Line Main Boom

Main Hoist
Auxiliary Hoist

Counterweight

Side Frame

Telescoping Boom Sections Crawler Tracks Carbody, Truck Frame

Base, Heel, or Foot Section

Swing Circle

Center Pin, Center of Rotation, Axis of Rotation

116
Rough Terrain Cranes

The rough terrain crane’s oversized tires

facilitate movement across the rough terrain
of construction sites and other broken ground.
Their short wheel base and crab-steering
improve maneuverability. In “pick and carry”
operations on rough terrain, however, they are
still subject to the same operating restrictions
that apply to other cranes.

Like carrier-mounted telescopic boom cranes,

rough terrain units are available with either full
power booms or pinned booms and the same
types of jibs and boom extensions. There are
two basic configurations.

FIXED CAB

Counterweight

Swing Circle
Operator’s Cab (Fixed)

Outrigger Beam

Outrigger Pads, Floats, Pontoons Outrigger Frame

117
Rough Terrain Cranes (continued)

ROTATING CAB

Boom Extension in
Stowed Position
Main Winch
Boom Hoist or Lify Cylinders
Auxiliary Winch

Counterweight
Operator’s Cab Rotates with Upperworks

Engine “On Carrier”

Outrigger Box
Pads, Floats, Pontoons Outrigger Beam

“A” Frame Jib in

Stowed Position

Operator’s Cab Rotates

with Upperworks

Engine

Cantilever Type
Outriggers

118
Rough Terrain Cranes (continued)

Like the carrier-mounted telescopic boom

cranes, rough terrain cranes can be equipped
with either full power booms or pinned booms
as well as with a variety of jibs and boom
extensions which can also be stowed on or
under the heel section of the main boom.

Boom Extension
in Stowed
Position

Boom Extension &

“A” Frame Jib in
Stowed Position

Boom Extension Mounted

“A” Frame Jib in Stowed Position

119
Heavy Lift Mobile Cranes

These cranes combine the best features of

derricks and lattice boom mobile cranes.
Typically they use very large extended
counterweights, masts and often roller rings
that move the boom’s fulcrum and the crane’s
tipping axis further away from the center of gravity.

Pendants Equalizer or
Bridle
Boom Hoist Reeving

Mast

Boom Pendants Counterweight

Pendants

Equalizer or Bridle

Boom Hoist
Reeving

Mast Counterweight

Counterweight
Pendants

Boom

Counterweight

Counterweight Roller Ring & Supports

Beam Carrier

120
Tower Cranes

Stewing ring

Fixed (non-stewing) tower

FIXED TOWER

FIXED TOWER

121
Hazards in Crane Operating Areas

Over 50% of all mobile crane accidents are the result of mistakes made when the crane was being
set up.

All of these accidents can be prevented by following the manufacturer’s recommendations for
assembly and dismantling, by using the correct components, and by observing the precautions
outlined in this section.

Remember: Improvising or taking shortcuts in assembly and setup can be fatal.

Use the checklist on the next page for reviewing the factors to consider in planning for crane and
hoisting operations.

122
PRE-JOB CHECKLIST
Whoever requires that a crane be used-project engineer, site superintendent, foreperson,
building owner, contractor, architect, or consultant – is as responsible for its safe operation as
the operator.
If a working area has not been adequately prepared for the crane, the operation will be unsafe,
regardless of machine capacity or operator skill. Consider the following factors.
• Can the machine get onto the site? Is the access road adequately graded and compacted?
Is the access ramp too steep?
• Will the machine have to travel over buried pipes, sewers, mains, etc., that might be
crushed?
• Is there room for the crane to maneuver in its designated position on site? Is there room to
erect or extend the boom? Can trucks hauling boom sections get into position and be
unloaded safely? Is there enough room and timber blocking to store boom sections
properly?
• Will an area be designated and roped off for use by the erection crew? Will it be large enough
for components to be stacked, handled, and assembled without endangering other site
personnel?
• Has the crane’s position been identified for every lift? What will the maximum operating
radius be? Will there be at least two feet of clearance between the counterweight and
nearest object? What obstacles or other hazards might be posed by existing buildings or
structures?
• Are operating areas graded, compacted, and levelled? Are they away from shoring
locations, excavations, slopes, trenches, embankments, etc., which could subside under
machine weight and vibration? Are operating areas over cellars, buried pipes, mains, etc.,
that may collapse?
• Will clearance and visibility be problems where other cranes, hoists, or equipment will be
operating? Will operators have a clear view of other equipment to avoid collisions and keep
hoisting ropes and loads from fouling? Will operators be provided with direct communication
to warn one another of impending danger? Will the overall lifting program be laid out,
controlled, and prioritized by one person in contact with all operators and each rigging
crew?
• Will crane operating areas be away from public traffic and access? Will signallers and
warning signs be provided when crane operations may overlap with public areas? Has
police cooperation been arranged to provide traffic and pedestrian control?
• Have operators been warned and have provisions been made to keep cranes from working
within a boom’s length of powerlines without
a) shutting off power
b) having the powerlines insulated, or
c) providing signallers to warn the operator when any part of the crane or load nears the
limits of approach specified by the Regulations for Construction Projects?

Voltage Rating of Powerline Minimum Distance

750 to 150,000 volts 3 metres (10’)

150,001 to 250,000 volts 4.5 metres (15’)
over 250,000 volts 6 metres (20’)

123
 Mark the location of all underground services that could be crushed
by the weight of the crane.

Fence or barricade areas in which personnel could be trapped and crushed.

124
Danger Areas

WHENEVER THERE IS THE

DANGER OF PERSONNEL
BEING TRAPPED OR
CRUSHED BY THE
COUNTERWEIGHT WHEN
THE CRANE SWINGS,
THE AREA SHOULD
BE BARRICADED.

MIN. CLEARANCE OF 2 FEET

No unauthorized
personnel in
swing area
during operation

Between counterweight
and carrier

Machinery deck

Outrigger Between upper works

during lowering and carrier

Try to keep personnel

out of this area

KEEP THIS AREA CLEAR OF

UNNECESSARY PERSONNEL.

125
Working Near Powerlines
High voltage electrocution is the largest single cause OPERATORS
of fatalities associated with cranes. All can be Before setting up to operate, look up. If
prevented. The power company or utility may there are powerlines, advise your
consider (if given advance notification) shutting down supervisor. The presence of overhead
the line temporarily or moving the line. If it is not powerlines may require a written work
possible to have the line moved or the power shut off procedure.
the following procedures should be enforced by the
project supervisor and strictly followed by all
operators. SITE SUPERVISION
Where a crane, hoist line, or load can
1. KEEP YOUR DISTANCE. Surrounding every live cross into the minimum distance to an
powerline is an area where an electric arc is overhead powerline, the constructor
capable of jumping from the powerline to a must have written procedures in place to
conductor of electricity. So you must keep all of prevent the crane, hoistline, or load from
your equipment and its load at least the minimum encroaching on the minimum distance.
permitted distance away from the powerline (see
page 6 for distances). If there is a chance for any
part of the hoisting operation to encroach on that
distance, protective measures must be taken to
prevent this encroachment. You must take these
measures unless you have controlled the hazard by
de-energizing or moving the lines, or by re-routing
the electricity around the work.

Note: The only exception to these requirements

occurs under both of these conditions:
• the powerline cannot be de-energized or moved, or
The crane boom could reach
the electricity re-routed, and within the minimum distance.
• under the authority of the owner of the electrical
conductor, protective devices and equipment are
PRE-JOB PLANNING
installed and written procedures are implemented
The time to take care of powerline
that are adequate to protect equipment operators
problems is during pre-job planning after
from electrical shock and burn.
the first site survey is made by a
This absolute limit of approach varies according to contractor. Take care of the problem
local, provincial, state and federal laws or crane prior to the crane’s arrival to avoid job
manufacturer’s recommendations, but is generally as delays and prevent accidents.
shown:

2. Treat all powerlines as live until reliable information assures you that the lines are de-energized.

126
Working near Powerlines (continued)

3. Identify the voltage of the service by checking markings on the utility pole and calling the utility.
When equipment or its load can encroach on the minimum permitted distance from a powerline,
the constructor must have written procedures in place to prevent the equipment or its load from
encroaching on the minimum distance.

Limit of approach Limit of approach

Need Do not need

signaller signaller

4. Have powerlines moved, insulated, de-energized, or follow the precautions in the Construction
Regulation. Insulating or “rubberizing” powerlines offers some protection in case of brush
contact in some circumstances. Your local utility may provide this service.

5. Place enough warning devices (such as signs) near the hazard so that the equipment operator
can always see at least one of them. The operator must be able to see them under all possible
environmental conditions (e.g., night, rain, fog). Signs must be specific about the hazard. They
should state, for example, “Danger! Electrical powerlines overhead.” CSAO recommends that
you include the voltage on the sign.

6. The operator’s station (e.g., driver’s cab) must

have a sign (such as a sticker) warning of the
hazard. The machine may come with a warning
sticker in the cab. Make sure it’s still legible.

7. A competent worker must be designated as a

signaller to warn the operator when any part of the
equipment, load, or hoist line approaches the
minimum permitted distance to a powerline. The
signaler must be in full view of the operator and
have a clear view of both the equipment and the
electrical conductor.

Taglines
will
conduct
electricity

127
Working near Powerlines (continued)

8. Avoid using tag lines. Unless it is necessary to

prevent the load from spinning into the
minimum distance to a powerline, the tag line
itself can be a hazard because it can swing into
the minimum distance.
Note: All ropes are capable of conducting
electricity, but dry polypropylene has better
insulating properties than most commercially-
available ropes.
Accidental contact
from powerline
swaying in the
9. Slow down the operating cycle of the machine wind
by reducing hoisting, booming, swinging, and
travel speeds.

10. Exercise caution when working near overhead lines having long spans as they tend to swing
laterally in the wind and accidental contact could occur.

11. Exercise caution when travelling the crane as uneven ground can cause the boom to weave
or bob into the lines.

12. Ensure that whenever cranes must repeatedly travel beneath powerlines a route is plainly
marked and “rider poles” are erected on each side of the crossing approach to ensure that
the crane structure is lowered to a safe height.

128
Working near Powerlines (continued)

IF YOU MAKE ELECTRICAL CONTACT WITH A POWERLINE

• Stay on the equipment. Don’t touch the
equipment and the ground at the same
time. In fact, touching anything in contact
with the ground can be fatal. If a new hazard
develops that could be life-threatening,
such as a fire, use the “bailout procedure”
(next page).
• Keep others away. No one else should
touch the equipment or its load – including
buckets, outriggers, load lines, or any other
part of the machine. Beware of time-
delayed relays: Even after electrical contact DO NOT
trips the breakers, relays may still try to PANIC

restore power. They may come on

automatically two or three times.
• Break contact. If possible – while remaining
inside the machine – the operator should try
to break contact by moving the equipment
clear of the wires. This may be impossible if
contact has welded conductors to the
equipment.
• Call the local utility. Get someone to call
the local electrical utility for help. Stay on
the equipment until the utility shuts down
the line and confirms that the power is off.
• Report the contact. Report every incident
of electrical contact to the local electrical
utility – they’ll check for damage that could
cause the line to fail later.
When the powerline is rated at 750 volts or
Inspect the
more:
wire rope
1. report the contact to the inspection and the
crane for
department of the Electrical Safety damage
Authority within 48 hours. caused by
the electrical
2. provide notice in writing to the Ministry contact.
of Labour and to the joint health and
safety committee, health and safety
representative, and trade union.
• Inspect the crane. The crane must undergo
a complete inspection for possible damage
caused by electrical contact. The electric
cur-rent could take several paths through
the crane, damaging bearings, electronic
controls, valves, and the crane’s cable. Wire
rope should be replaced. Damage to the
wire rope – such as welding, melting, or
pitting – may not be visible.

129
Working near Powerlines (continued)

BAILOUT PROCEDURE
If the operator decides to leave the machine, he must jump clear. He must never step down
allowing part of his body to be in contact with the ground while any other part is touching the
machine.

WRONG RIGHT (BUT STILL DANGEROUS)

The operator should never leave the
machine unless absolutely necessary.

HIGH VOLTAGE CONTACT will result in electrical

current flowing down the boom and through the
crane to ground. The ground will then be energized
with a high voltage near the crane and lower
voltage farther away.

Because of the hazardous voltage differential in the ground, the operator should jump with his feet
together, maintain balance and shuffle voltage slowly across the affected area. Do not take large
steps because it is possible for one foot to be in a high voltage area, and the other to be in a lower
voltage area. The difference between the two can kill.

130
Working Near Transmitters

When operating near radio, TV or microwave transmitters the crane boom and load can become
electrically charged. The boom acts like an antenna and becomes “hot”. The charge is not
electrically dangerous when compared with the effect of contacting electricity but it can cause
burns to personnel handling loads. The greatest danger to personnel exists when they “jump” from
the effect of this shock and fall or trip.

Grounding the crane will not likely have any effect. The only real solution is to insert a synthetic
web sling between the crane’s load block and the load. This will isolate the riggers from the crane
and protect them from burns. The crane operator will not be affected when in the machine but
should wear rubber gloves when getting on and off the crane.

131
Factors Affecting Crane Capacity

Capacities and other information included in the load charts for cranes are based on almost perfect
conditions seldom achieved under actual operation.

It is vital to know not only how to determine capacity correctly from the chart but also to recognize
the factors that can reduce a crane’s capacity below the chart ratings.

These factors, described on the following pages, include:

• poor machine condition

• variations in boom angle
• variations in load radius
• errors in boom angle indicators during critical lifts
• quadrants of operation
• sweep area
• tires not clear of the ground
• division of sweep area into quadrants
• improper use of outriggers
• soft footing
• crane not level
• sideloading
• increase in load radius
• rapid swing rate
• impact loading
• rapid acceleration or deceleration of load
• duty cycle operations
• high wind speeds.

The information concludes with an illustration of proper setup.

132
Poor Machine Condition

Load chart ratings apply only to cranes maintained in condition as good as new and as stipulated
by the manufacturer. The boom is one of the more critical elements of the crane and must be in
perfect condition at all times.

Sway
Check for
hydraulic
leaks.

Droop

Never use a boom section

with a bent lattice member;
the bent members draw in
the main chords.
Check telescopic booms for conditions such as:
• Sway
• Droop
• Cracks around the hinge pin
• Rust (could be sign of crack)
• Flaking or cracked paint
(could be sign of overload)
• Bulges, creases or waviness
of the plates in the boom
(could be signs of overload)
• Worn pads.
Picture frame
Check end fittings for cracks.
must be
square.
Check
sheaves.

Check condition of all pendants &

end fittings and look for broken
wires around the sockets.

Check all welds

for cracks and Welds can be the
corrosion. initiation point for
cracks.

Boom must be
straight and
not twisted.
Dents can reduce
boom strength
considerably.

Check condition
of all boom hoist
ropes and
If a chord is even slightly damaged or bent, sheaves.
don’t use it. Don’t try to repair it. Chords are
so vital to the strength of the boom that it is
not practical to attempt repairs.

133
Boom Angle

The capacities listed in the load chart are also based

on and vary with the boom angle of the machine.

On telescopic boom cranes the boom angle is the

angle between the base (bottom) of the heel section
of the main boom and the horizontal while the boom
is under load.

Boom
Angle

Boom
Angle

Because of boom and machine

deflection (and pendant stretch on
lattice booms) expect the boom angle
to lower somewhat from its unloaded
condition once a load is applied.
Expect even larger boom angle
reductions when the crane is “on
rubber” because of tire deflection.

134
Load Radius

The capacities listed in the load chart also depend on and vary with the crane’s load radius.
The load radius is the horizontal distance measured from the center of rotation of the crane (center
pin) to the load hook (center of gravity of the load) while the boom is loaded.

Unloaded Radius

Loaded Radius

Because of boom and machine deflection and pendant stretch, expect the load radius to increase
when the load is lifted off the ground. Expect even larger increases in radius when the crane is “on
rubber” because of tire deflection.

Load Radius Load Radius

135
Boom Angle Indicators and Critical Lifts

Boom angle indicators are required on all mobile cranes but they must not be relied on for accuracy
during critical lifts because:

• They can give as much as a 2° reading error in boom angle which can substantially affect the
gross capacity reading on the load chart.
• The indicators are mounted on the base section of the boom and may not register the deflection
of the extended sections under heavy load particularly if the wear pads are worn excessively.
Consequently the boom angle may actually be lower than the indicator reads.

For these reasons, using boom angle indicator readings during critical lifts can be misleading. Rely
on load radius (where possible) or if the boom angle must be used (for example when lifting from
a jib) assume the correct reading to be lower than what the indicator actually says.

Boom deflection
at tip

Increase in
load radius

Almost no deflection at base

136
Importance of Quadrants

The leverage and capacity of a crane change during rotation of the upperworks. Leverage and
capacity are also affected by the location of the tipping axis. For these reasons the crane’s stability
can change during operation.

To provide uniform stability, regardless of the position of the upperworks relative to the carrier, the
crane’s capacity is adjusted by the manufacturer according to the quadrant of operation.

These capacity changes are

identified in the load chart by
the quadrant of operation.

As the crane
swings from
“over the rear”…

Tipping Axis

to “over the side”…

Tipping Axis

to “over the front”, its C of G moves

closer and closer to the tipping
axis, thereby reducing its stability.

Tipping Axis

137
Sweep Area

The sweep area is the total area that the crane boom can swing over.

The sweep area is divided into operating areas called quadrants of operation. The crane’s capacity
is then based on the quadrants.

Sweep Area

138
Division of Sweep Area into Quadrants
The crane is said to be in a particular quadrant of operation when the load hook is located over
that portion of the sweep area.

Caution: Not every make and model of crane

can be operated in all of these quadrants.
The diagrams are for reference only. Consult
load charts to determine quadrants of operation
for particular makes and models.

“Over the Side”

Crane’s Quadrant
of Operation = “Over the Rear”
“Over the Front”
(Because the load
hook is above that
portion of the
sweep area.)

“Over the Side”

“Over the Front”

“Over the Side”

“Over the Side”

Crane’s Quadrant of Operation = “Over the Rear”

“Over the Side”

Crane’s Quadrant
of Operation =
“Over the Idler End”

“Over the Drive End”

“Over the Side”

139
Improper Use of Outriggers
The load chart ratings of carrier-mounted and rough terrain
mobile cranes apply to three base configurations:
• “On Outriggers”
• “On Tires”
• Partially Extended Outriggers

“On Outriggers”
Full chart ratings apply only when:
• all outrigger beams are fully extended, and
• all tires are clear of the ground.

Partially Extended Outriggers

In special circumstances a crane may be operated on outriggers
that are not fully extended. In this situation the crane must be
equipped with load charts coinciding with this partial extension
of the outriggers and there must be a method of measuring the
outrigger extension.

CRANE HAS “ON OUTRIGGERS” RATING

“ON TIRES” RATING

Crane does not have “on outriggers”
rating because rear outriggers are not
extended and set. This machine’s
capacity is limited to the “on tires”
load chart.

Outriggers not extended and set.

140
Improper Use of Outriggers (continued)

“ON TIRES” RATING

Full “on outrigger” ratings do not apply because
the carrier wheels are touching the ground.

PARTIALLY EXTENDED OUTRIGGERS

Load charts must be supplied for this partial
extension. Otherwise use “On Tires” rating.

“ON OUTRIGGER” RATING

Full “on outrigger” ratings apply because
• all beams are fully extended
• all tires are clear of the ground.

Tires should be just clear of the ground to keep ram length

as short as possible and thus minimize rocking action.

“On Tires”

Full chart ratings apply only when:

• tires are per manufacturer’s specifications
• tires are in good condition
• specified tire pressure is maintained, and
• crane speed does not exceed manufacturer’s
specifications.

For working “on rubber” some manufacturers recommend

extending the outrigger beams but keeping the rams
partially retracted so that the floats are just clear of the
ground.

141
Soft Footing

Load chart ratings apply only when the ground

conditions are firm enough to support the crane and
keep it level during the lift. If the ground is soft or
unstable, the tires, crawlers or outriggers will sink or
subside causing loss of capacity. In almost all
cases, heavy duty blocking having large bearing
areas will be necessary to prevent sinking and
provide a solid base for the crane.

Use solid blocking under all floats

Poor Float Poor Float Support Poor Float

Support Support

On soft ground or on
backfilled material, timber
or steel mats must be
used to prevent the crane
from sinking or setting.

142
Crane Not Level

All load chart ratings are based on the machine being

perfectly level in all directions. This applies to cranes
“on crawlers”, “on tires”, “on outriggers” and when
travelling with load.

One of the most severe effects of being out-of-level is

that side loads develop in the boom. Because of side
loads all mobile cranes lose capacity rapidly as the
degree of out-of-level increases.

A crane is
dead level
when the
hoist rope
is in line
with the
center line
of the
boom.

Dead Level As out-of-level increases,

No Side Load sideloading increases.

Being level is critical to the capacity of a crane. If out Similar information can be obtained from
of level, there is possible capacity loss. The table the manufacturers for all cranes.
below demonstrates this relationship for a particular Machines that are used on barges are
crane. provided with “list charts” that identify
crane capacity with barge list (expressed
as degrees). Capacity loss due to barge
Boom Chart Capacity Lost When
Crane Out of Level By
list is the same as capacity loss due to
Length
and an out-of-level condition on ground.
Lift Radius 1° 2° 3°

Short Boom, 10% 20% 30%

Minimum Radius
Short Boom, 8% 15% 20%
Maximum Radius
Long Boom, 30% 41% 50%
Minimum Radius
Long Boom, 5% 10% 15%
Maximum Radius

143
Crane Not Level (continued)

Caution: If the crane is not level the load chart does

not apply. You must either level the crane by using
its outriggers or level the ground the machine is
resting on.
Even though the crane might have been properly
levelled during set-up, ground subsidence during
operation can cause an out-of-level condition.
Check level frequently.

It is also important to note that when a crane is set up

off level, swinging from the high side to the low side
increases the operating radius. It also increases the
load on the turntable, on the outriggers and on the
supporting frame structure.

Low Side Radius High Side Radius

Boom Topples

Swing Uphill Swing Uphill

Caution: A boom at maximum elevation (minimum radius) on the low side cannot be swung over
to the high side without risking collapse of the boom over the cab.

144
Sideloading

Load chart ratings apply only when the load is

picked up directly under the boom tip. If the load
is to either side of the boom tip, sideloading
occurs and decreases capacity. This applies to
both lattice and telescopic booms and is one of
the most common causes of boom failure. It
usually causes structural failure and always
occurs without warning.

• Sideloading • Sideloading
occurs when the occurs when a load
crane is not level. is dragged or pulled
sideways.

This can buckle the

boom, damage the
swing mechanism or
overturn the crane if
the boom is at a
high angle.

145
Sideloading (continued)

• Sideloading occurs
whenever a load is
swung rapidly or when
the swing brake is
applied suddenly.

• Tilt-up operations can

cause sideloading of
the boom.

146
Increase of Load Radius

Load chart ratings apply only when the hoist line is vertical at all times and the load is freely
suspended during the lift. If the line is not vertical, regardless of the reasons, capacity is lost. In
addition to the examples relating to sideloading (see previous pages), the following conditions
produce non-vertical hoist lines which result in increased load radius and reduced capacity.

• Reaching beyond the vertical extends the load

radius and tends to draw the boom forward and
decreases the crane’s capacity. It will tip or fail
more easily and with a lower hook load than
listed in the load chart for the boom tip radius.

• Rapid swing causes increased load radius which

decreases stability and reduces capacity.

Chart Radius Increase

• Lifting inside the boom tip radius puts a load

component on the boom that acts to tip it
backward. After the load is clear of the
ground, it will swing out increasing the radius
and tend to tip the crane forward.

147
Increase of Load Radius (continued)

With Load – “Over Rear” With Load – “Over Side”

No Load With Load – “Over Rear”
No Load

• Working “on rubber” can also produce an increase of load

radius. When lifting a heavy load “over the rear”, “on rubber”
the crane will lean slightly toward the load. This is caused by
boom, tire and carrier deflection. This lean increases when
picking “over the side” “on rubber”. The lean will increase
operating radius so the load will swing outward once it
clears the ground. This outswing is dangerous to anything in
the path of the load. The increase in load radius may also
overload the machine. To overcome outswing, boom up as
the load is lifted to maintain a constant radius.

“Over the Side”

“Over the Rear”

• Swinging a load from “over the end” to “over the side” will
increase lean. This is especially noticeable when operating
“on tires”. Since tilt acts to increase load radius, it must be
compensated for when swinging the load. Swing slowly.
Change boom angle (raise or lower boom) while swinging to
maintain a constant radius and prevent inswing or outswing
of load.

148
Rapid Swing Rate

Load chart ratings apply only when the load is vertically in line with the boom tip at all times. Rapid
swing rates make this an impossible condition to meet.

Therefore, load chart capacities do not allow for fast swings. The swing rate must be adjusted to
keep the load directly below the boom tip at all times.

(1) START SWING (2) DURING SWING (3) STOP SWING

佣 佣 佣

(1) When the swing is started the load (2) Rapid swinging of a load causes it (3) When the crane’s swing is stopped,
will lag behind the boom tip causing to drift away from the machine the load will keep going causing
sideloading and reducing capacity. increasing the load radius and sideloading and reducing capacity.
reducing capacity; the load will also
lag behind the boom tip causing
sideloading.

149
Rapid Swing Rate (continued)

Caution: On long boom mobile cranes, rapid swing

rates, rapid swing acceleration, or rapid application of
the swing brake can overturn the crane or collapse the
boom with or without load on the hook.

• Moving the dead weight of the boom at the start of a swing or trying to stop it at the end of a
swing causes the boom to sideload itself.
• The centrifugal force of the boom during a high speed swing creates a high forward tipping load.
• At high boom angles, the boom can collapse over the back of the machine if the boom is
accelerated or decelerated rapidly.

150
Impact Loading and Rapid Acceleration
or Deceleration of Load

Load chart capacities do not allow for sudden starting or stopping of the load, impact loading or
sudden machine movements.

The following situations create such conditions and reduce crane capacity below the chart ratings.

• Sudden release of a load • Sudden snatching

causes a rapid change in of a load causes
load and impact impact loading
loading. Crane will and the hoist
recoil initially, then rope or boom
full weight of load can fail.
will suddenly be
applied to the hook. Ease into all
The result can be loads to avoid
overturning or impact loading.
structural failure.
The same thing can
happen when a
frozen, caught or
stuck load is
pulled and
suddenly
breaks free.

• Sudden release
of a load causes
the boom to
recoil and
perhaps topple.

Place all loads

gently to allow
boom deflection
• Rapid hoist and pendant
acceleration stretch to
produces hook gradually return
loads higher to normal.
than the
actual load
weight.

151
Impact Loading and Rapid Acceleration
or Deceleration of Load (continued)

• Rapid stopping of the load

produces hook loads
higher thant the actual
load weight (see table).

Brakes • “Pick and Carry” operations subject the carrier and

applied boom to shock loads. In order to ensure that the chart
capacities are not exceeded, move the crane and load
Stopping as smoothly as possible.
distance

Load stops

• Don’t extract pilings, casings or similar loads by

Sudden brake application during lowering will increase the yanking or jerking on them. The practice of pulling on
hook load. Below is an example of how line speed and the load until the machine has tipped, then releasing
stopping distance impact the load on the hook. Note how the hoist line, allowing the machine to drop back and
rapidly the loads increase as the stopping distance catching the hoist line on a clutch or brake may break
decreases. the boom. If the piling or casing won’t dislodge with a
smooth, steady pull, use an extractor, pulling frame or
INCREASE IN HOOK LOADS similar device.

LINE STOPPING DISTANCE (FT)

SPEED • Demolition work can be particularly hazardous. Shock
FT/MIN. 10 6 2 loadings and sideloadings during work with demolition
balls and clamshell buckets can be severe. The
repetitive nature of such work imposes heavy demands
100 0.4% 0.7% 2.2%
on all parts of the machine. Restrict demolition ball
150 1.0% 1.6% 4.9%
weights to not more than 50% of capacity (“on rubber”
200 1.7% 2.9% 8.6% capacities for truck cranes) at the maximum radius at
250 2.7% 4.5% 13.5% which you handle the ball, with the boom length you are
300 3.9% 6.5% 19.4% using. In addition to this requirement, ensure that the
350 5.3% 8.8% 26.4% ball weight never exceeds 50% of the available line pull.
400 6.9% 11.5% 34.5%

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Duty Cycle Operations

Full load chart ratings may not apply when cranes are used in high speed production operations
(duty cycle operations) such as concrete placing, steel erection, draglining, clam, magnet or
grapple work.

The manufacturer will either specify in the load chart that lift crane ratings be reduced by a
percentage (usually 20%) for duty cycle operations or will supply a separate load chart for such
operations.

The capacity reduction is recommended because the speed of these operations produces
increases in crane loads from sideload, swing-out and impact as well as higher temperatures in
critical components such as brakes, clutches, pumps and motors.

The following are duty cycle operations:

• Draglining, Clam, Grapple and

Magnet Operations

• High Speed, High Volume

Concrete Placement

• High Speed, High Volume Steel Erection

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High Wind Speeds

Almost all crane manufacturers specify in the load chart that chart ratings must be reduced under
windy conditions, and they may also recommend a shut-down wind velocity. In almost all cases,
when the wind speed exceeds 30 mph, it is advisable to stop operations.

Wind affects both the crane and the load, reducing the rated capacity of the crane. Never make a
full capacity lift if it is windy. Use a great deal of discretion even when lifting under moderate wind
conditions of 20 mph.

It is advisable to avoid handling loads that present large wind-catching surfaces. The result could
be loss of control of the load and crane even though the weight of the load is within the normal
capacity of the crane.

A 20 mph wind exerts a force of only 11⁄8 Ib/ft2 on a flat-surfaced load (the force on a 4 ft. by 8 ft.
sheet of plywood = 36 Ibs.) so only loads having very large sail areas would require crane capacity
derating. At 30 mph, however, the wind exerts a force of 2.53 lb/ft2 of flat surface area (equals 80
Ibs. on a sheet of 4 ft. by 8 ft. plywood). This wind force on the load at 30 mph is enough to cause
non-vertical hoist lines and loads that are very difficult to control.

Boom strength
is most affected
when the
wind is from
the side.

SAE XJ1093 specifies

that booms be designed
to withstand their full
rated load plus a side
load equal to 2% of the
rated load plus a 20
mph wind from the side.
Boom strength is
therefore adequate to
handle winds from the
side up to 20 mph but
no allowance is made
for the effect of the wind
on the load.

154
Setup Summary

A crane is properly set up for lifting when the following conditions are met.

For Cranes Operating “On Outriggers”

Boom angle, boom length and load radius are known

The hook is and the crane’s rated capacity is known.
directly above
the load’s
C of G.
Rigging is
correct.

Outrigger pads are

on solid footing
or blocking.

Load weight is known.

All wheels are clear of ground.

Crane is level.
All outrigger beams are extended as prescribed by manufacturer.

For Crawler-Mounted Cranes or When Lifting “On Rubber”

Boom angle, boom length and load radius are known

and the crane’s rated capacity is known.

The hook is
directly above
the load’s C of G.

Rigging is
correct.

Crane is set
up level on
Load weight firm, stable
is known. ground or
blocking.

155
Machine Selection

One basic requirement for any crane safety program is making sure that the right machine is
selected for the job. If crane characteristics do not match job requirements, unsafe conditions are
created before any work is done. Job site personnel are forced to “make do” and improvise in a
rush – a surefire recipe for accidents

CHECKPOINTS
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
• 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.

156
RESULTS
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.

The crane must be

matched to:
Lift Height (H)
Lift Weight
Lift Radius (R1 R2 R3)

THE CRANE MUST BE PROPERLY MATCHED TO THE JOB

157
Those responsible for equipment selection must ensure that the crane is going to be safe and
reliable for as long as it will be used, and under all anticipated conditions to which it will be
exposed during operation.

Certain equipment considerations and requirements apply to all cranes. These requirements can
be specified in purchase orders and rental agreements. Machines should be rented only from
reputable suppliers. Note that all cranes of the same model number may not have the same
capacity rating. The correct rating should be determined from the manufacturer through the serial
number.

Any changes in counterweight and boom inserts made by the owner should be checked. After such
changes, capacities and other data in the load chart may no longer apply.

A machine designed, manufactured, inspected, tested, and maintained in accordance with

Canadian Standards Association Standard Z150-1998 Mobile Cranes should meet the
requirements of all major codes and regulations.

Signalling
Signalling is an important part of crane operation,
but is often not treated with the respect it
deserves. Signallers must be used whenever:
• the operator cannot see the load
Telephone or “hardline”
• the operator cannot see the load’s landing area communications are
best but…
• the operator cannot see the path of travel of the
load or of the crane
• the operator is far enough away from the load to
make the judgment of distance difficult
• the crane is working within a boom’s length of
the approach limits to powerlines or electrical
equipment.

2-way radios can be of value for

Where loads are picked up at one point and almost all signalling operations.
lowered at another, two signallers may be required
– one to direct the lift and one to direct the
descent.

Hand signals should be used only when the

distance between the operator and the signaller is
not great and conditions allow for clear visibility.
The international hand signals for hoisting appear
on the following page.

Telephone or radio communications between

operator and signaller can be extremely effective.

158
HOISTING HAND SIGNALS

159
Notes

160
Notes

161
Notes

162
Notes

163
Notes

164
Notes

165
Notes

166
Notes

167
Notes

168