Lifting Acessories Safety

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Occupational Safety and Health Guides and Instructions 12

Lifting Accessories

Safety

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION

Tampere 2007


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ISBN 978-952-479-064-2

ISSN 1456-3614

Multiprint Oy, Tampere 2007


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INTRODUCTION .........................................................................................................5General requirements for lifting accessories ................................................................6

Structure ....................................................................................................................6

Safety factor ...............................................................................................................6

Machinery Decision requirements apply also to lifting accessories

custom-built for individual uses ...................................................................................6

Use and inspection ....................................................................................................7

Procurement ..............................................................................................................8

Lift planning .............................................................................................................8

GUIDANCE AND TRAINING .......................................................................................9

MARKINGS AND LOAD TABLES ...................................................................................9

FACTORS TO OBSERVE DURING LIFTING ...................................................................11

CHAIN SLINGS .........................................................................................................12

Structure ..................................................................................................................12

Chain ......................................................................................................................12

Equipment ...............................................................................................................13

Inspection and rejection criteria for chain slings ........................................................15

WIRE ROPE SLINGS ..................................................................................................15

General ................................................................................................................... 15

Inspection and rejection criteria for wire rope slings ..................................................16Synthetic round slings and lifting belts ......................................................................17

Material ..................................................................................................................17

Markings .................................................................................................................18

Working load limit ....................................................................................................18

Sharp edges and edge protection .............................................................................19

Operating instructions for synthetic slings ................................................................19

Inspection and condition monitoring of lifting belts and round slings ....................... 19

Maintenance and repair ...........................................................................................20

LIFTING CLAMPS .....................................................................................................21

When using clamps ...................................................................................................21

Special operating instructions for screw clamps ........................................................22

LIFTING TONGS ......................................................................................................22

Inspection .................................................................................................................22

LIFTING MAGNETS ...................................................................................................23

VACUUM LIFTERS .....................................................................................................24

LIFTING FORKS ........................................................................................................25

LIFTING BEAMS ........................................................................................................ 25

Table of Contents


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4 Lifting Accessories Safety

LOOSE LIFTING GEAR ......................................................................... 26

Lifting lugs .......................................................................................... 26

Lifting lug dimensions ........................................................................ 26

Welded lifting lugs ............................................................................. 26

Lifting eye bolts and nuts ................................................................... 26Inspection .......................................................................................... 27

SHACKLES ........................................................................................... 27

Inspection ........................................................................................... 27

Lifting accessories custom-built for individual use ................................ 28

Regulations and instructions ............................................................... 28

APPENDIX 1 Lifting accessory inspection report ................................... 29

APPENDIX 2 Hand signals ................................................................... 30


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Lifting Accessories Safety 5

Introduction

Lifting and transfer operations typically entail

some risk factors that cannot be totally elimi-

nated. The danger area generally cannot be

isolated entirely to prevent the transferred load

from causing danger to those participating in

the lifting operation or to others nearby. The

lifting appliance operator and load handler each

play a crucial role in ensuring a safe lifting op-

eration. However, as the lifting appliances used

in industry become more and more radio-con-

trolled, the operator increasingly also performs

the role of load handler.Compared to many other types of work

equipment, lifting appliances have a central role

in terms of safety, as failure of practically any

one of their parts can result in a hazard situa-

tion.

The idiom that a chain is only ever as strong

as its weakest link also applies well to the lift-

ing operation. The lifting accessory and its

operation must be monitored and controlled

throughout its lifespan. Failure of even a single

link will result in danger.Customers are interested in not only the

product itself, but also the operational quality of

the company that produces or supplies it. High

quality is demanded of production and of the

production environment, and a low incidence

of damage or accidents is considered by the

customer to be a key measure of quality. Provi-

sion of clear operating instructions indicates to

the customer that quality-conscious and safe

operations are being observed.

The transfer and transportation of materials

and personnel is the main accident black spot

for many fields of industry. According to some

estimates, nearly half of all industrial accidents

are related to lifting or transfer operations.

The size and weight of lifted loads has in-

creased, and accidents that occur are often

serious in terms of occupational safety as well

as financially. Accidents are almost equally

influenced by technical factors as human fac-

tors. A significant proportion of accidents are

considered to be caused by substandard or

totally lacking pre-planning, with lift planning

too often consisting solely of in-situ arrange-

ments made between the site foreman and the

employee.

On the other hand, the structural safety of

lifting accessories is considered to be reason-

ably high. Inspections are arranged in a high

proportion of companies, but the level and

scope of these inspections is variable. Lifting

slings are, at least, inspected by the seller, but

without the users own established inspection

procedure this can create a false sense of se-curity. Accidents can occur at any time ahead

of the next scheduled inspection. Faulty lifting

accessories must therefore be immediately iden-

tified and repaired or, if necessary, taken out of

use completely.

Finnish regulations concerning lifting and

transfer appliances are based on the Occupa-

tional Safety and Health Act.

The objective of this publication is to create

a data file which can be workplace-specifically

supplemented and used to define a set of pro-cedures aimed at ensuring that loads and the

lifting of them is better planned, and that em-

ployees are competent in the use of safe lifting

methods and can fully rely on the lifting acces-

sories they work with.

Any procedures found to be beneficial can

be incorporated into the companys quality sys-

tem and occupational safety action plan.

These guidelines focus on practical work-

place level operations and the models and

solutions presented in them are based on the

common tasks and problems encountered at

this level.

The guidelines are based on information

gathered from legislation, standards, studies,

information from insurance companies and sup-

pliers of lifting accessories, occupational safety

and health inspectorates and experts in the

field.

Information needed at the workplace for the

planning of instructions for the procurement

and inspection of lifting accessories, the plan-


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ning of lifting operations and practical guidance

has also been included. The guidelines also aim

to take current legislation and other norms and

instructions into consideration.

The guidelines cover the most commonly

used lifting accessories as well as lifting acces-

sories that are custom built for individual, spe-

cialised uses.

General requirements for lifting accessories

Structure

The lifting of a load requires a lifting appliance

and a lifting accessory.

A lifting accessory refers to a component ordevice that is not permanently fitted to the lift-

ing appliance and that is used between the lift-

ing appliance and the load, or fixed to the load

to enable it to be lifted.

Requirements concerning the structure of

lifting accessories are presented in the Gov-

ernment Decision on the Safety of Machines

(1314/1994, as amended) which came into

force on 1 January 1995. The decision, herein-

after referred to as the Machinery Decision, ap-

plies to all lifting accessories taken into use andbrought onto the market after 1 January 1995.

The Machinery Decision requires manufac-

turers of lifting accessories, their authorized

representative established in the European Eco-

nomic Area or manufacturers that assemble lift-

ing accessories from ready components to draw

up a Declaration of Conformity for the lifting

accessory and to affix CE marking to it.

A Declaration of Conformity can also be

given for product batches.

Safety factor

Lifting accessories each are assigned a specific

safety factor. The safety factor consists of a safe

working load limit set below a given safety

margin. The limit ensures that no immediate

danger will occur if the maximum safety load

is exceeded. The safety factor does not give

the operator licence to exceed the working

load limit, rather it provides a safety margin to

compensate for the weakening of the lifting

appliance during normal use due to wear and

ageing, jolting during lifting and inaccuracies in

load weight estimations.

Machinery Decision requirementsapply also to lifting accessoriescustom built for individual uses

Appendix 1 of the Machinery Decision presents

the essential safety requirements concerning

machinery and Chapter 4 of Appendix 1 of the

decision addresses, in particular, the essential

safety requirements concerning the structure

of lifting accessories. The same chapter also

presents, e.g., the working coefficients (safety

factors) of different lifting accessories.According to the Machinery Decision, each

lifting accessory, attached machine plate or

equivalent marking position must be marked

with the following:

manufacturers details

raw material information, if required for

compatibility purposes

working load limit

CE marking

In addition, each lifting accessory or lifting ac-

cessory batch sold as a unit must include an

instruction manual containing at least the fol-

lowing information:

standard operating conditions

use, assembly and maintenance instructions

restrictions on use

Lifting gear such as lifting lugs, lifting eyes

and shackles that are used in conjunction with


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Procurement

Procured equipment must be suitable for its

purpose of use. Operating and maintenance in-

structions in Finnish and, if necessary, in Swed-

ish must always be obtained from the lifting

accessory supplier.

Operational safety can be increased by

procuring lifting accessories that cannot be

accidentally or unknowingly used incorrectly.

The procurement of lifting accessories should

be concentrated on a few reliable suppliers,

as this ensures better provision of advice and

expert help and user training if needed. The

procurement of new lifting accessories can also

be centralised at the workplace. This task is ide-

ally suited, for example, to the lifting accessory

inspector who is responsible for registering the

lifting accessories in the companys monitoring

system.

Lift planning

The planning of lifting operations should be

integrated as part of productions material han-

dling planning, the objective of which is the

economical, flexible and safe handling of prod-

ucts. All future lifting requirements should be

considered at the products planning stage.

Good lift operation planning and the correct

choice of lifting accessory can effectively elimi-

nate the worst operating errors and hazards in

advance. The designer of the lifted item mustdetermine how and with which lifting acces-

sories the lift is to be performed, determine the

points of lift and, as necessary, add lifting eyes,

lifting lugs or threaded holes for fastening lifting

eye bolts. At the planning stage, lifting instruc-

tions must be prepared for the product. The

lifting operations and transfers needed during

the different production stages of the products

subcomponents must also be taken into consid-

eration in the lift plan.

A set of permanent instructions should be

drawn up for the load handling and lifting of

frequently recurring similar items.

Special lifting operations such as heavy lifts,

lifting of large items and joint lifting operations

always require a separate written plan.

To ensure a balanced lift, the weight, shape,

lifting position and centre of gravity of the

load must be determined. Mark the weight

and centre of gravity of the lifted item in the

drawings.

The lifted item must be kept balanced and

under the control of the lifting appliance op-

erator throughout the lifting operation.

To prevent sliding or falling of the lifted item,

the load supports, points of attachment and

lift route must be planned.

Choose a lifting accessory that is compatible

with the load, the lifting appliance and theoperating environment:

- choose a sling that is long enough to

guarantee a safe sling angle and prevent

overloading

- determine how the weight is to be divided

between the sling legs

- take into account the lifting frequency

- reserve sufficient room for the lifting

operation

- use edge protection as necessary.

Check the landing platform and the load

supports to ensure that the lifting accessories

can be removed both safely and without

damage.

If necessary, perform a test lift to verify the

secure fastening of the load.

Ensure the lifting accessories are inspected

and necessary user guidance is provided.


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Guidance and training

In order to avoid accidents, personnel involved

in lifting operations must be provided with

training and guidance in safe lifting practices

appropriate to the work quality and working

conditions in question.

Effective work guidance can influence em-

ployee attitudes towards safety. Right attitudes

can prevent accidents.

Risk factors should be analyzed and written

manuals drawn up as necessary.

Responsible persons and spheres of responsi-

bilities must be clearly defined.

The employee must observe all instructions,

regulations and take due care in their opera-

tions. The employee must also notify the fore-

man and occupational safety and health repre-

sentative of any perceived faults or deficiencies.

A record should be kept of all lifting opera-

tion training and guidance provided. This ena-

bles monitoring and checking of the type and

date of guidance and/or training received by

each employee. It also facilitates the planning

of new and supplementary training and helps

avoid overlapping of training content.

Markings and load tables

Each lifting accessory must be marked with

its designated working load limit. The lifting

accessory must not be used if this marking isnot displayed. Overloading is forbidden at all

times.

A suitable sling type must be chosen and its

loading instructions strictly observed. The great-

er the angle of inclination of the sling legs (sling

angle), the less load the sling can support. The

correct sling angle can be determined via load

tables. Use of load tables must be mastered by

all lifting operation personnel.

In the new standards and tables, the angle

of inclination of the sling leg (sling angle) refers

to the angle between the sling leg and the

vertical. A higher than 60 angle of inclination

(120 leg angle, i.e. angle between sling legs,

according to the former system) must not be

used. The angle of inclination equals half theleg angle .

The working load limit for a multi-legged

sling depends on the number of sling legs and

the sling angle factor as determined by the

angle of inclination and the leg configuration

(hitch).

Outdated load markings should be changed

in accordance with the new standards to avoid

confusion.

Harmonised practices at the workplace

should be adopted in a controlled manner and

through provision of employee training.


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Factors to observe during lifting

The hook of the lifting appliance and lifting

accessory must be equipped with a safety

latch or other reliable backup such as a self-

locking hook.

For each lifting operation, check that the

master link is compatible (i.e. big enough)

with the lifting appliances hook.

The weight and centre of gravity of the lifted

load must be known.

Ensure that the lifting sling used is long

enough.

The distance between the points of attach-

ment must be big enough to ensure a secure

load balance during lifting.

Sliding of the sling must be prevented using

a lifting boom as necessary.

Never lift or move the load over personnel orleave the load unnecessarily suspended.

Ensure that the load is set squarely in the

bowl of each sling hook to avoid incorrect

loading of the hooks.

Take into account the effect of choker lifting:

reduces the working load limit by 20%.

Protect the sling from any sharp load edges.

Lifting slings, especially round slings and lift-

ing belts, are susceptible to damage from

sharp load edges. Sharp edges can signifi-

cantly weaken the strength of the lifting ac-

cessory and present a sudden hazard. The

best form of protection against sharp edges

is the use of edge padding designed for

this purpose. Any sharp edges on the load

should, as far as possible, be removed at the

production stage.

A preliminary lift should always be carriedout: once the load is raised free of its base,

stop the lift and check the load balance and

fastenings.

Avoid jolting during loading (e.g. due to

sudden starts and stops), and never swing

laterally, lift laterally or drag the load along

the ground.

Never attempt to manually stop a heavy load

from swinging.

Never lift using the bindings used for bun-

dling the load if they are intended only for

load binding.

Never pull a sling from beneath the load if

the load is resting on the sling.

Store slings in their designated storage

places.


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Chain slings

Structure

Chain slings are lifting accessories comprised of a chain and connected lifting gear. They can be sin-

gle or multi-legged.

Each sling must be fitted with a marking plate displaying the working load limits for different

loading situations.

A visual inspection must be carried out before using the sling to verify that the sling and sling

fittings are in due order.

Chain slings can typically be used at maximum load in a temperature range of -40C to +200C.

The manufacturers instructions must be observed for operation in temperatures outside this range.

Chain slings should have a designated storage place (e.g. rack) where they are not susceptible

to damage and can be easily obtained. Load tables and lifting instructions should also be located at

the storage place.

Figure 2

Chain slings

Chain

The chain consists of steel links. Lifting slings must be made of short link chain only.

Figure 3

Chain

The required properties of the chain are stipulated in the relevant standards for sling chains.

Documents specifying the technical properties of the chain must be readily available during chain

sling assembly.

Any fittings attached to the sling must be at least as strong as the chain itself.


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Equipment

Master link

One or more sling legs are connected to the master link via a suitable connection method.

Figure 4

Master links

For each lifting operation, check that the master link is compatible with the lifting appliances hook(i.e. big enough).

Hook

Sling hooks must consist of self-locking hooks or sling hooks equipped with a sufficiently strong

safety latch.

Figure 5

Different hook models

Open hooks may be used only in special cases where it is ensured that no hazard to personnel,

nearby objects or materials will be created during the lifting operation.

The load must always be set squarely within the hook bowl.

The hooks safety latch must be of sufficient strength and laterally supported to be able to fully

withstand the loading and operating stresses.


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Other equipment

Mechanical connector

Connectors are used in chain sling assemblies to connect its various components.The hitch configuration system ensures that components of the wrong size cannot be connected

to each other.

Sling importers each supply connectors that are compatible with their own chains.

Figure 6

Examples of mechanical connectors

Marking plateEach chain sling must be fitted with a marking plate showing its designated working load limit. The

marking plates of standard SFS-EN 818-4 compliant slings contain the information shown in Figure 7.

Figure 7

Chain sling marking plate

ShortenersIn order to balance the load, length adjustment of the chain sling legs is needed.

Shorteners consist of shortening clutches, shortening hooks or quick-acting chain length regulators

which lock the chain in place with spring-loaded pegs.

Figure 8

Slings equipped with

different types of chain shorteners

The impact of shortening hooks on the chains strength must be verified and users informed of any

restrictions.

Before beginning the lifting operation, check that the chain is securely locked in the shortener

and unable to come loose at any stage during the lift.

1. Working load limit

2. Nominal chain diameter

3. Number of sling legs4. Sling angle marking

5. CE marking


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Inspection and rejection criteriafor chain slings

Chain slings must be measured and their entire

length inspected during periodic inspections.

The lengths of the different legs of multi-legged

slings must be compared. Special considera-

tion must be paid to possible stretching, wear,

cracking, deformation and external damage of

the different sling parts. Detailed link-by-link

inspection is the only means of detecting these

damages. The cause of the perceived damage

must always be clarified and steps taken to pre-

vent the fault from recurring.

The inspection must be made in accordance

with the manufacturers instructions. Chainsling inspections are usually based on the fol-

lowing rejection criteria:

A chain sling must be taken out of use if:

The slings working load limit for different

load situations is not clearly marked on the

sling.

The slings master link, hooks or other com-

ponents contain bends, fractures, warping,

other deformation or the hook mouth has

opened more than 10%.

Any chain link has worn more than 10%. The

chain links are measured in two planes. Their

average dimensions must be at least 90%

of their original dimensions. In this way, the

level of wear until the next inspection can be

predicted.

Slashing, notching, pitting or corrosion

caused by external factors is more than 10%

of the material thickness, or the degree of

deformation is visually perceptible.

Colour change caused by heat damage is

perceived.

Damage caused by weld splash is perceived.

The mechanical connector is worn, bent,

warped or cannot turn freely.

Wire rope slings

General

Wire rope slings are lifting accessories made from steel rope with a ferrule-secured or spliced sling

eye at each end. Sling eye fittings include links and hooks. When using eye fittings and attach-

ments, eye thimbles must be used to protect the sling eye. Wire rope slings can be single-legged or

multi-legged.

Figure 9

Typical wire rope slings

Always carry out a visual check before using the sling to ensure that it contains no faults that may

jeopardise safety. The interval between periodic inspections depends on the degree of strain of use.


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During periodic inspection, check the condition

of the sling paying particular attention to its

markings and any damage or wear that may af-

fect the safe use of the sling.

working load limit marking for different

loading situations

broken or worn wires

rope deformation (e.g. kinks, bird caging)

warped ferrules, splices or terminations

heat damage

corrosion

In addition to a visual inspection, other methods

must be used as necessary, such as non-destruc-

tive testing to determine the condition of the

inner parts of the sling.

Inspection and rejection criteriafor wire rope slings

Wire rope slings must be inspected along their

entire length during periodic inspection. Special

consideration must be paid to possible stretch-

ing, wear, cracking, deformation and external

damage of the different sling parts. The cause of

the perceived damage must always be clarified

and steps taken to prevent the fault from recur-ring. The inspection must be made in accord-

ance with the manufacturers instructions.

Wire rope sling inspections are usually based on

the following rejection criteria:

Broken wires

Wire breaks are usually caused by mechanical

damage or corrosion. They reduce the strength

of the rope and can cause hand injury to the

user.

The sling must be rejected and replaced if

any strands are totally broken, wire breaks occur

very close to each other or the number of wire

breaks exceeds 5% of the total number of wires

along a length equal to six times the diameter

of the rope.

The sling must be rejected if the nominal di-

ameter of the rope has worn by more than 10%

at any point.

Rusting and corrosion

Corrosion may occur if the sling is incorrectly

stored or used in corrosive conditions.

Surface rusting may also be a sign of inter-

nal corrosion, the extent of which is difficult to

estimate. In this case the rope must be opened

up to assess its internal condition.

The sling must be rejected if a significant

degree of internal corrosion is found, or corro-

sion is found in the splice.

Deformation

The sling must be rejected if it contains defor-

mation caused by kinks, bird caging, crushing,core failure or knots.

Heat damage

Colour changes of steel ropes can be a sign of

overheating. Overheating damages the fibre

core and weakens the ropes lubrication. The

manufacturers instructions must be observed

regarding the permissible operating tempera-

tures.

Damage of sling eye fittings and

attachments

Special attention must be paid to the following

points:

opening up and cracking of hooks

deformation and wear of links or thimbles

ferrule cracks

crushing or wear of ferrule or splice

slide-through or looseness of splice or ferrule

wire breaks concentrated near the ferrule or

splice or in the splice

the effect of the sling eye spreading force at

the head of the sling eye if an oversized pin

or wrong thimble type is used

breaking wires on the outer surface of the

sling eye, e.g. if a soft eye and thin pin has

been used

effect of friction on the load-bearing surface

of soft sling eyes.


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Markings

Round slings and lifting belts must have the fol-

lowing markings:

manufacturers/sellers details

nominal strength = WLL (working load limit:

nominal loads under 1,000 kg are expressed

in kilograms and nominal loads above 1,000

kg in tonnes).

safe working load (working load limit) at dif-

ferent sling angles

sling/belt material indicated by coloured

label.

CE marking

length

traceability code must be available. A doublemarking label can also be used, i.e. a backup

label is fixed beneath the stitched marking

label.

Table 2 Sling angle factors for round slings

The following documents must be readily avail-

able:

operation, assembly and service instructions

Declaration of Conformity, including:

name and address of manufacturer or supplier

description of sling/belt

applied standards

Working load limit

The sling angle factors and working load limits

for different sling angles are shown in the in-

struction tables provided by the manufacturer

or importer. These tables should be kept at the

site of use of the lifting slings.

Table 3 Sling angle factors for lifting belts


Straight lift Choked lift Basket lift Basket lift

WLL 0,8 WLL 2 WLL 1,4 WLL 1 WLL 0,7 WLL 0,5 WLL

Straight lift Choked lift Basket lift Basket lift

WLL 0,8 WLL 2 WLL 1,4 WLL 1 WLL


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Sharp edges and edge protection

Contact of the lifting sling with sharp edges

during the lifting operation dramatically re-

duces the slings strength. Burs, load imbalance,

stop/start jolting during lifting or worn slings

further increase the damaging effect of sharp

edges.

A sharp edge with a corner radius of 1 - 7

mm reduces the load-bearing capacity of lift-

ing belts and round slings by 50%. With lifting

belts, a 13 mm corner radius is required to

maintain a load-bearing capacity close to that

of straight lifting.

According to experience, edge protection

must be used whenever the corner radius is be-low 7 mm.

A wide range of edge protection types and

materials are available for specific applications.

Operating instructions forsynthetic slings

Before lifting, perform a visual inspection of

the full length of the sling and check that the

working load limit is clearly marked.

Only use slings that are in full working order.Take into account the effect of the lifting

method on the load. Do not exceed the

working load limit.

Be wary of sharp edges and coarse surfaces.

Use edge protection.

Ensure the load remains balanced for the en-

tire lifting and transfer operation.

The lifting hook must be big enough with

respect to the belt width and the hook edges

must be rounded off. Ensure that the sling is

set squarely in the bowl of the hook and is

evenly loaded.

The leg angle of hooked eye belts must not

exceed 20 degrees.

Never tie knots in the sling. Knots weaken

the strength of the sling, endanger the lifting

operation and may ruin the sling.

For load temperatures over 80C follow the

manufacturers instructions.

Chemicals and solvents can damage the

sling.

Avoid sharp stops/starts by slowly accelerat-

ing and decelerating during the lift.

Avoid any kind of jolting during the lifting

operation.

Lower the load onto its landing platform so

that the sling can be removed without dam-

aging it. Do not forcefully remove the sling.

If multiple slings must be used simultane-

ously due to the length of the load, prevent

sliding of the lifting accessory in the lifting

hook and on the load.

Inspection and condition monitoringof lifting belts and round slings

Lifting belts and round slings are more suscepti-

ble than other lifting accessories to damage and

must therefore always be condition checked

before each use.

Lifting belts must be visually inspected along

their entire length on both sides for surface

damage, longitudinal or transverse band cut-

ting, edge cutting, wear damage and stitch or

eye damage.

The condition of round slings must be esti-

mated according to the condition of their outercoating, as the load-bearing yarns are sealed

within the coating. In addition to visual inspec-

tion, the condition of the load-bearing yarns

must be felt to verify that they are free of any

hardening and that the core is regular in shape.

Some hardened areas felt inside the sling may

be due to tape bindings used in round sling

manufacture.

Users of lifting belts and round slings must

be given sufficient guidance in their condition

assessment. In addition, a competent expert

must check the condition of the slings at least

once a year and verify their suitability for use

with respect to the existing lifting conditions.

One-time-use slings are often supplied with

new machinery for purposes of moving it and

lifting it into position. These throwaway slings

must be disposed of immediately after use.



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A lifting belt must be taken out of use if:

The working load limit marking is not clearly

visible.

The belt has been overloaded.

The belt contains a knot.

The belt has extensive abrasion damage or is

generally worn and dirty.

More than 10% of the warp yarns (load-

bearing yarns) are severed or yarns are dam-

aged on the belt edge.

The weft yarns are broken along a more than

5 cm length.

Slash damage or abrasion damage of the sur-

face exceeds 10% of the transverse direction.

Damage has been caused by chemicals, heat

or moisture.

Yarn breaks exist at the belt terminations or

the terminations are considerably worn.

The joint stitching has come unstitched.

A round sling must be taken out of use if:

The working load limit marking is not clearly

visible.

The sling has been overloaded.

The inside of the sling is damaged.

The sling contains a knot.

The outer coating is broken to the extent

that the inside is visible.

The outer coating shows signs that a welding

spark, lathe chip or equivalent has damaged

the load-bearing yarns.

The sling cover has extensive abrasion dam-

age or is generally worn and dirty.

Damage to the load-bearing yarn has been

caused by chemicals, heat or moisture.

Maintenance and repair

Do not attempt to carry out repairs yourself.

Dirtied lifting belts and round slings can be

washed in tepid water using a neutral deter-

gent.

Lifting belts and round slings that have been

wetted during washing or otherwise must be

left to dry in either a hanging or laying position.

They must not be spin-dried.

Store synthetic slings in a well ventilatedspace on a rack designed for the purpose so

that they are not susceptible to chemicals, sol-

vents, ultraviolet radiation, temperatures over

70C or varying climatic conditions.

Remember to only use round slings and lift-

ing belts that fulfil strict quality requirements.

Observe the instructions provided by the manu-

facturer and refer any problems encountered to

the manufacturer.



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Lifting clamps

Clamps are used for lifting plates and sheets, profiled products and pipes. The holding force is typi-

cally based on the grip between the clamps toothed eccentric cam and the surface of the lifted

item.

Figure 12

Lifting clamps

1. Body

2. Lifting eye

3. Cam segment

4. Safety latch

5. Spring

6. Cam segment shaft7. Lifting eye shaft

8. Pivot

Lifting clamps must show the following

markings:

working load limit

minimum and maximum thickness or width

of lifted itemsproduction/serial number

name of manufacturer/supplier

CE marking

In addition, the clamp must be marked with

any possible use restrictions. The operating in-

structions, maintenance and inspection instruc-

tions and Declaration of Conformity included

with each clamp delivery must be observed.

Clamps that are not equipped with safety lock-

ing to safeguard against accidental loosening of

the load must not be used for vertical lifting of

plates or sheets.

When using clamps

Check that the clamp is in order and suitable

for use and that the surface hardness of the

lifted item does not exceed the maximum

surface hardness permitted for the clamp.

The clamp must be compatible with the

lifting appliances hook and, if necessary, a

chain sling with a sufficiently large ring must

be used.

Do not exceed the working load limit.

Check that the contact surface is free of scale,

paint, dirt, ice, grease or other substances that

may weaken the holding capacity.

Always observe the designated loading di-

rection of the clamp. The clamp must be

positioned to follow the lifting direction of

the sling.

Pendular motion of the fastened item must

be prevented, as this can damage the

clamps cam teeth. When lifting long plates

or sheets, two or more clamps and lifting

booms should be used.

Lift only one plate or sheet at a time when

vertical lifting with a plate/sheet lifter.



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At least two pairs of horizontal clamps

should be normally used. Do not exceed the

maximum sling angle specified by the clamp

manufacturer.

When turning or moving, always keep the

end of the plate/sheet or lifted load towards

you. Lifting above personnel is strictly forbid-

den.

Wear of the contact surfaces of the lifting

clamps cam segment and counter jaw must

be monitored and inspection intervals short-

ened as necessary.

If the clamp has undergone repair, its opera-tion must be checked by means of a test lift.

Special operating instructionsfor screw clamps

The clamp must be compatible with the lift-

ing task. For example, clamps that base their

holding capacity solely on the manual tight-

ening force of the screw must not be used

for vertical lifting of plates or sheets.

The holding force is based on the friction

force between the cam segments and the

surface of the lifted item, so the clamps must

have toothed, hardened cams.

The optimum holding force is attained if

the cam section includes a swivel joint thatwedges the jaw more tightly closed as lifting

commences.


Lifting tongs

Lifting tongs are used for lifting round parts or

bundles. Their holding force is based on thecurved shape of their arms and the leverage

effect. The broader the tongs, the better their

holding capacity.

Their holding capacity can be improved by

coating the gripping arms to increase friction.

The specified working load limit for the tongs

must not be exceeded. The load diameter must

also conform to the specified maximum/mini-

mum limits.

The same documentation must be observed

upon delivery of the tongs as with clamps.

Inspection

Observe the instructions provided by the manu-

facturer, paying special attention to deforma-

tion, warp and cracking. Check the operation

of the tongs and their locking function (should

lock when in the open position), the tightness

of the screws, shaft wear and the tong mark-

ings.

Figure 13 Lifting tongs


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Lifting magnets

There are two basic types of lifting magnet on

the market: permanent magnets and electro-

magnets. In addition, electrically connected

permanent magnets offer a third, intermediate

alternative.

Electromagnets include mains current and

standby battery operated accumulator models.

The advantage of permanent magnets is their

minimal maintenance and simple structure.

Figure 14

Lifting magnets

1. Magnet

2. Instruction plate

+ type plate3. Lifting eye

4. Release arm

5. Release button

6. Pole shoes

The lifting capacity of lifting magnets is derived

from the magnetic field that forms between the

magnet and the lifted item.

Factors affecting the size of this magnetic

field and, thus, the load holding power include:

Lifting capacity reduces with reduced contact

surface area of the magnet shoes.

The magnet shoes must be clean and

smooth. They must not be machined. Any ir-

regularities must be carefully ground smooth.

Thin-walled items do not create an effective

magnetic field.

The surface quality of the lifted item.

Air gaps strongly reduce the lifting capacity.

Air gaps result from surface unevenness,

burs, scale, grease, paint etc.

The shape of the lifted item. When lifting

round and curved items, rounded pole shoes

must be used to achieve a sufficient contact

surface. In this case the lifting capacity is al-

ways lower than when lifting flat items.

The overall dimensions of the lifted item.

Long items tend to bend, creating air gaps atthe edges of the magnet.

Position of the magnet. Standard magnets

can be lifted only in the horizontal position.

Variable magnetism of lifted items. Some ma-

terials do not magnetize at all. The optimum

holding capacity is attained with unalloyed

low-carbon steel.

The weight of the lifted load must be propor-

tioned according to the magnet manufactur-

ers instructions.

Magnets must not be used in high tempera-

tures. The manufacturers instructions must

be observed in this respect.

The holding capacity of the magnets must

be checked at regular intervals by test lifting

using the same loads typically lifted by the

lifting magnets.


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Vacuum lifters

The vacuum lifter is a lifting accessory equipped

with one or more suction cups. The adhesive

force between the load and the suction cup is

created by means of a vacuum.

Vacuum lifters usually operate by means of

vacuum pumps, blowers or ejectors but they

can also be mechanically operated without a

pump.

The shape of the suction cup is selected ac-

cording to the shape and quality of the load,

e.g. round, angular or oval. The suction cups

can be flat, for lifting flat items such as plates,

sheets, panels and glass panes.The contact surface of the suction cups can

also be specially moulded for the lifting of

pipes or other non-flat items.

Figure 15 Vacuum lifters

a) piston

b) cylinder

c) sealing ring

d) vacuum chamber

e) valve

f) reverser

g) torque rod

h) chain

i) rubber diaphragm

j) pressure chamber

k) alarm whistle

l) dust cover

m) bleed valve

In addition to the required lifting capacity,

the shape of the lifted load and its surface qual-

ity must also be taken into consideration in the

choice of vacuum lifter.

Lifters should be designed to provide double

the holding capacity required for the heaviest

load lifted. Vacuum lifters may not be used for

conveying hazardous materials. Loaded lifters

must never be lifted above personnel. If neces-

sary, the danger area must be isolated.


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Lifting forks

The same rules apply to lifting forks as to other

lifting accessories. Most hazardous situations

that arise when operating lifting forks involve

falling loads. Attention must therefore be paid

in the design and user instructions of the lifting

fork to ensure sufficient fastness and stability of

the load during the lifting operation.

User instructions and a Declaration of Con-

formity must be included in the lifting fork

delivery.

During periodic inspection of the lifting fork,

visually check for any permanent deformation

of the structures and wear of the wearing parts.Check the joints of the structure, especially

welded joints, to ensure there are no visually

apparent cracks. If the lifting fork operation

involves any mechanical functions that stabilise Figure 16 Standard lifting fork

Figure 17 Lifting beams

Lifting beams

A wide range of different loading capacities,shapes and lengths of lifting beam are availa-

ble. Lifting beam components and other equip-

ment should also be optimally designed to suit

the beams specific function.

Lifting beams or spreader beams can effec-

tively reduce the load stresses on the sling or

on the load itself.

Lifting beams are the ideal lifting accessories

for workspaces with limited headroom where

the use of lengthy top rigging is not possible.

The lifting beam designer and manufacturer

must have the necessary expertise in lifting

beam design and production, including suffi-

the lifting fork or load during the lifting opera-

tion, the functions and the wear of the compo-

nents involved must also be inspected.

cient knowledge of material strengths and struc-tural requirements. Lifting beams must have the

following markings:

working load limits for different loading situ-

ations

dead weight of the beam, to enable deter-

mination of the lifting appliances payload

capacity

production/serial number, name of manufac-

turer

and CE marking

The following must be observed upon delivery

of the lifting beam:

operating instructions,

including possible re-

strictions on use

maintenance and in-

spection instructions

and assembly drawing

Declaration of Con-

formity


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LOOSE LIFTING GEAR

Lifting lugs

Lifting lug dimensions

The dimensioning of lifting lugs takes into ac-

count the loads exerted on them. For example,

the force exerted on the sling leg is also ex-

erted on the lifting lug in the direction of the

sling leg. In single-legged direct lifting, the full

weight of the lifted load is exerted on the lifting

lug. Dimensioning must also take into account

possible asymmetry of the load, in which case

the load will not be exerted evenly on all lugs.In addition, it must be ensured that the load

itself can withstand the stresses exerted on it.

If the lifting lugs are used as loose lifting gear

(i.e. not welded), they must either be marked

with their working load limit or their rated ca-

pacity and possible restrictions on use must be

specified in the operating instructions provided

upon delivery.

Welded lifting lugs

The traditional lug model consists of a bracket

thermally cut from steel plate with a hole for

shackle attachment. The design must take into

account the load exerted on the lifting lug, the

loading direction and the suitability of the point

of attachment to a welded joint. Welded lifting

lugs designed and manufactured to withstand

loading in all directions according to the rated

capacity marked on the lug are also available

on the market. These lugs usually consist of around, high-tensile lug and weldable fastening

pieces.

Figure 18 Welded lifting lug

Lifting eye bolts and nuts

Lifting eye bolts are loose lifting gear. They

must either be marked with their working load

limit or their rated capacity and possible restric-

tions on use must be specified in the operating

instructions provided upon delivery.

Figure 19

Lifting eye bolt

The model that is still extensively used is the

DIN580 and DIN582 compliant lifting eye bolt.

The bolt can be loaded only vertically or at an

angle of max. 45 degrees in the direction of the

lug eye.


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The safest models are those marked with

working load limits set within sufficient safety

margins in all loading directions. The lug eye

should also be able to swivel freely after fasten-

ing, so the screw itself is protected from loosen-

ing or over-tightening under stress.

Inspection

Visually check that the thread of the eye bolt

and fastening hole are intact and that the eye

bolt is free of deformation.

Shackles

Shackles used for lifting must be designed for

the lifting task in question.

Shackles are loose lifting gear.

As such, they must either be marked with

their working load limit or their rated capac-ity and possible restrictions on use must be

specified in the operating instructions provided

upon delivery.

Always fully tighten the shackle pin before

lifting. Fixed joints and attachments that can-

Figure 21 Shackles

not be continuously monitored must be fitted

with e.g. a cotter to prevent the pin from open-

ing. Loading of the shackles should be perpen-

dicular to the pin.

Inspection

Visually check that the pin thread is intact and

that the shackle is free of fracture or deforma-

tion.


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Lifting accessories custom-built for individual use

Lifting accessories that are capable of meet-

ing the specific requirements and frequently

recurring lifting operations of the workplace

often have to be custom-built or self-built as

they are not available on the market as series

products. The Machinery Decision, which came

into force at the beginning of 1995, emphasises

the responsibility of the manufacturer also with

regard to such lifting accessories made for indi-

vidual use.

Lifting accessories must be designed and made

so that they are compliant with the require-ments for provision of a Declaration of Con-

formity and CE marking.

Preconditions for CE marking

Risk factors concerning the lifting accessory

and the lifting operation must be known and

a risk assessment must be performed.

Risk factors must be eliminated through safe-

ty design or safety devices and clear warning

given of remaining hazards.

Essential health and safety requirements con-

cerning the lifting accessory must be clari-fied.

The lifting accessory must be designed and

manufactured to comply with safety require-

ments.

Operating instructions must be drawn up

and necessary markings made.

A Technical File with drawings and strength

calculations must be compiled and the nec-essary tests performed.

Regulations and instructions

Occupational Safety and Health Act (No. 738/2002,

(OSH Act))

The OSH Act sets out the general regulations

concerning occupational safety.

Government Decision on the safety of machinery,

so-called Machinery Decision (1314/1994, as

amended)

This government decision contains the proce-

dures and essential health and safety require-

ments concerning the bringing of lifting acces-

sories onto the market.

The decision lays down the obligations for the

manufacturer, importer and seller.

Government Decision on the procurement, safe use

and inspection of workplace machinery and other

equipment, so-called Work Equipment Decision

(856/1998, as amended)

This government decision specifies the require-

ments concerning machinery and equipment

used at the workplace and lays down the obli-

gations for the employer.

SFS Handbook 79, Lifting accessories

Finnish Standards Association manual contain-

ing official regulations, standards, instructions

for the selection, use and storage of lifting ac-

cessories and inspection and rejection criteria.


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Appendix

Appendix

LIFTING ACCESSORY INSPECTION REPORT No.

NAME OF LIFTING ACCESSORY: __________________________________________________________

DEPARTMENT AND PRECISE LOCATION:___________________________________________________

MANUFACTURER / SELLER________________________________________________________________

PURPOSE OF USE:_______________________________________________________________________

WORKING LOAD LIMIT: CE MARKING Y N

SERIAL NUMBER: _______________________________________________________________________

INSPECTION INTERVAL:__________________________________________________________________

INSPECTED BY DATE FAULT(S) OBSERVED

COMMISSIONING Y N

ANNUAL INSPECTION Y N






PARTS LIST

PHOTOGRAPH

DRAWING

TECHNICAL DESCRIPTION

0

kg

45

kg

60

kg

SERIAL NUMBER

INSPECTION INTERVAL


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Hand signals

General hand signals

START both arms outstretched horizontally to the side,

Attention palms facing forward

Start of signal

STOP right hand raised, palm facing forward

Halt/Pause

End of movement

END hands clasped at chest height

of action

Vertical movements

LIFT right hand raised with palm forward,

circle slowly

LOWER right hand down with palm facing backward,

circle slowly

VERTICAL hands indicate actual distance

DISTANCE


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Lifting Acessories Safety

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