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Course: CRANE Rigging and Lifting

TRAIN THE TRAINER

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Rigging and Lifting Course | 2

Day 1 Outline

Module Description

Module 1 Rigging and Lifting Regulations

Module 2 Safe Systems of Work

Module 3 Housekeeping

Module 4 Planning and Execution of Lifting Operation

Module 5 Lifting Equipment

Module 6 Rigging Principles and Terminologies

Module 7 Communication

Module 8 Awareness of Lifting Operation

Written Assessment
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Q&A
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Module 1 – Rigging and Lifting

Regulations

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Module 1 – Rigging and Lifting Regulations
Overview | 4

 The Provision and Use of Work Equipment Regulations (PUWER) 1998

 Lifting Operations and Lifting Equipment Regulations (LOLER) 1998

 Approved Code of Practice (ACoP)

 Under Section 20 of the Health and Safety in Employment Act 1992

Note:

 PUWER 1998 applies to all equipment provided for use at work

 LOLER 1998 is additional for lifting equipment

 PUWER 1998 and LOLER 1998 must be complied for lifting equipment

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Module 1 – Rigging and Lifting Regulations
Scope of PUWER1998 | 5

 Applies to all equipment provided for use at work

 The equipment provided must be:

a) Suitable for the intended use

b) Safe for use

c) Used only by competent people

d) Accompanied by suitable safety measures, e.g., protective devices,

markings, warnings
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Module 1 – Rigging and Lifting Regulations
Scope of LOLER1998 | 6

 Applied to cranes, lift trucks, goods lifts, vehicle inspection hoists,

ropes, bell hoists, vehicle tail lifts, chain slings, eyebolts etc.

 It covers the following:

a) All equipments must be thoroughly examined by a competent

person

b) Planning of lifting operations

c) Safe operation of equipment

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Module 1 – Rigging and Lifting Regulations
Application of PUWER 1999 and LOLER 1998 | 7

 PUWER 1998 and LOLER 1998 apply to:

a) Employer and self employed who provide equipment for use at work

b) Employees

c) Those in control of equipment

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Module 1 – Rigging and Lifting Regulations
Approved Code of Practice (ACoP) – Duties of Employer
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 Employer must:-

a) Provide and maintain a safe working environment

b) Provide and maintain facilities for the safety and health of employees at work

c) Ensure that machinery and equipment is safe for employees

d) Provide Protective Clothing and Equipment

e) Ensure that working arrangements are not hazardous to employees

f) Provide procedures to deal with emergencies that may arise while employees are at
work

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Module 1 – Rigging and Lifting Regulations
Approved Code of Practice (ACoP) – Duties of Principal
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 Principals engaging contractors are required to take all practicable

steps to ensure that:

a) no employee of a contractor or subcontractor, or

b) if an individual, no contractor or subcontractor is harmed while doing

any work (other than residential work) that the contractor was
engaged to do.

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Module 1 – Rigging and Lifting Regulations
Approved Code of Practice (ACoP) – Duties of Self-Employed | 10

 Every self-employed person shall take all practicable steps to ensure

that no action or inaction of the self-employed person while at work
harms the self-employed person or any other person.

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Module 1 – Rigging and Lifting Regulations
Approved Code of Practice (ACoP) – Duties of Employees | 11

 Every employee shall take all practicable steps to ensure:

a) Their own safety while at work (including using protective clothing

and equipment)

b) That no action or inaction of theirs while at work causes harm to any

other person

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Module 1 – Rigging and Lifting Regulations
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Personal Responsibilities

 Stay safe and remain alert in sites/facilities

 Understand and abide to company safety policies

 Abide to warning signs pasted in sites/facilities

 Use PPE and equipment as instructed

 Report all hazards

 Report and document all defects immediately

 Never throw items from height

 Only competent people are allowed to operate equipment and machineries

 No horseplay in sites/facilities
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Module 2 – Safe Systems of Work

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Module 2 – Safe Systems of Work
Permit to Work (PTW) | 14

 What is PTW?

Formal written authority to operate a planned procedure, which is designed to protect

personnel working in hazardous areas or activities.

 PTW validity?

Lasts for one working shift or should not exceed 16 consecutive hours

 Receiver of PTW?

a) Company employees certified by department head to sign and receive work permits

b) Sponsoring organization heads (contractor)

• Cancellation/Suspension of PTW

a) Job safety does not meet the conditions specified on the work permit.

b) Emergency situation.

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 Module 2 – Safe Systems of Work | 15

Toolbox Talk
 What is Toolbox Talk?

a) Safety lecture to educate workers about safe work conditions

b) Also knows as “Toolbox Meeting” or “Tailgate Meeting”

c) Required to be carried out for all work with significant safety exposure

d) Final check in the hazard assessment process and the start of work
implementation

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Module 2 – Safe Systems of Work | 16

Toolbox Talk
 When does it take place?

a) Must take place at job site with all workers before starting the work

b) Must take place at job site when major changes or different phases of work is started

 What are being discussed/covered:

 Work plan

 Hazards and Controls

 Roles and Responsibilities

 Emergency procedure

 Personal protective equipment

 Previous incidents and lesson learnt

 Questions & resolution of issues raised by workers

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Module 2 – Safe Systems of Work | 17

Example of Toolbox Talk Checklist

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Module 3 – Housekeeping

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Module 3 – Housekeeping
Importance of Good Housekeeping | 19

 Housekeeping must be carried out before, during and after rigging and
lifting activity

 Good housekeeping:

a) Ensure items are securely stored to avoid hazardous situations e.g.

fire hazards

b) Ensure equipments and accessories are well kept and maintained

with time

c) Reduce injuries e.g slipping and tripping due to oily/wet floor

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Module 3 – Housekeeping
Examples of Good Housekeeping | 20

Poor housekeeping and

work procedures due to
inadequate site and work
area supervisions

Equipments and materials

are organized and stored

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Module 3 – Housekeeping
Examples of Good Housekeeping | 21

Good housekeeping ensures safe workplace 21

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Module 4 – Planning and Execution of Lifting

Operation

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Module 4 – Planning and Execution of Lifting Operations
Overview
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Define the Lift

 Risk Assessment
Planning  Work Environment Conditions
 Categorization of Lifting Operation
 Lift Plan
Preparation
 Toolbox Talk to communicate Lift Plan
Execution  Execute lifting operations
 Control Access to lift areas for safety
 Reacting to changing conditions e.g. Stop Work
Learn & Record Policy for any unsafe condition or action

 Discuss and improve Lift Plan

 Learning points
 Feedback on equipment effectiveness,
lifting techniques, personnel etc
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Module 4 – Planning and Execution of Lifting Operations
Define the Lift
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 Has this particular lifting operation has been carried out?

a) If Yes, risk assessment and Lift Plan might already exist. Assess
them to confirm they are still applicable

b) If No, a competent person will prepare a Lift Plan

 How to define a lift?

a) Load weight, shape, centre of gravity and availability of adequate

lifting points

b) Initial and final load positions and how it will get there

c) The environment in which the Lifting Equipment will be used

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Module 4 – Planning and Execution of Lifting Operations
Planning Stage – Risk Assessment | 25

 For every lifting operation, the risks have to be assessed and controlled

 As part of the Hazard Effect Management Process (HEMP), a risk

assessment is carried out prior to any lifting operation to identify
associated hazards, their severity and likelihood of occurrence

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Module 4 – Planning and Execution of Lifting Operations
Planning Stage – Risk Assessment | 26

 HEMP addresses:

a) Planning the lift

b) Identifying the hazards and restricted areas

c) Selecting competent personnel

d) Specifying the minimum number of people to conduct the lifting operation

e) Selecting Lifting Equipment

f) Communicating lift requirements and hazards

g) Procedures for changing the Lift Plan

h) Emergency, recovery and contingency plans

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Module 4 – Planning and Execution of Lifting Operations
Planning Stage – Risk Assessment
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 Risk Assessment Matrix (RAM) is used to determine risk. The objective

is to ensure all tasks have Low Risk through elimination or adequate
control

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Module 4 – Planning and Execution of Lifting Operations
Planning Stage – Sample of RAM | 28

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Module 4 – Planning and Execution of Lifting Operations
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Planning Stage – Example of Risk Assessment Log

Activity Potential Hazards Control Measures

Lifting • Defective components • Examine all equipments before

• Unsafe equipment use
• Hazardous wind conditions • Destroy defective components
• Hazardous weather • Competent person to examine
conditions equipment
• Electrical contact • Suspend lifting activity during poor
weathers
• Maintain minimum permitted
distance from live overhead power
line
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Module 4 – Planning and Execution of Lifting Operations
Planning Stage - Work Environment Conditions | 30

 Environment conditions specific to the work location identified and accounted for in
planning and execution of all lifting operations

 Develop contingency plans and procedures to manage changes in environmental

conditions

 Parameters to include:
1. Sea state
2. Weather
3. Visibility
4. Noise
5. Communications
6. Terrain stability or slope
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7. Surrounding operations and installations
8. Site access and egress
Module 4 – Planning and Execution of Lifting Operations
Planning Stage – Categorization of Lifting Operation
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 Categorize and control lifts according to complexity and risk. There are 2
categories of lift:

Routine Non-Routine

• Routine crane operations • Simple lifting operations using

• Repetitive lifting operations Loose Lifting Equipment
using the same equipment (e.g. • Complicated lifting operations
drilling activities) e.g. tandem lifting
• Routine lifting operations with • Complex / Critical / Heavy lifting
Loose Lifting Equipment operations requiring a Lift Plan
with engineering input

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• May use generic Lift Plan • Must use dedicated Lift Plan
Module 4 – Planning and Execution of Lifting Operations
Planning Stage – Sample of Lift Plan | 32

LIFTING OPERATION PLAN PAGE 1 of

Location: Area:

Permit Number: Risk Assessment Number:

Generic Lifting Plan No: Method Statement Number:

Is Diagram/Sketch/Calculations Of Lifting Operation Enclosed? YES/NO nr.:

Description Of Lifting Operation:

Lift Category: Routine: Non-Routine:

Weight Of Load: Actual / Assessed (delete as appropriate)

Lifting Equipment & Accessories to be used (specify type ,SWL and colour code)

All Lifting Operations Require The Following To Be Considered But This List Is Not Exhaustive.

 Cultural, communication and language difficulties  Conflicting tasks in area


 Weight, size, shape and centre of gravity of load   Environmental conditions including weather and
 permissible limits
 Availability of approved lifting points on load   Lighting in the pick-up and lay-down areas; 

 Method of slinging/attaching/detaching the load  Proximity hazards, obstructions, path of load 
  Working under suspended loads 
 Overturning/load integrity/need for tag lines
  Access and emergency escape routes 
 Suitability and condition of lifting equipment to be
used  Experience, competence and training of personnel 
 Initial and final load positions and how it will get there  Number of personnel required for task 
 Ground and underground considerations  Pre-Use Inspection of equipment by operator 

 Lifting over live equipment  Visibility of the load
 
 Number and duration of lift(s)
 



Task Details (Step By Step)

Method(s) Of Communication To Be Used Radio      Verbal      Hand Signals 

Steps Taken To Eliminate Danger To Personnel Involved and Others (including barriers where appropriate):

De-brief and learning points:

Prepared By/Name: Signature: Date:

Reviewed By/Name: Signature: Date:

Approved By/Name: Signature: Date:

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Module 4 – Planning and Execution of Lifting Operations
Execution Checklist
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Module 4 – Planning and Execution of Lifting Operations
Planning Overview | 34

• Weight size
• Center of • Determine SWL
gravity • Select slings, shackles, eyebolts,
chain, block, etc

• Location
• Obstruction

• Determine crane location

• Determine working area
• Radius, lifting height, lifting weight,
boom length

• Study crane loading chart

• Select crane
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Module 4 – Planning and Execution of Lifting Operations
Preparation Overview | 35

• Check lifting points

(Lifting lug)

• Check slings, shackles,

etc. • Complete lifting plan
• Check condition • Prepare Lifting PTW
• Check color coding & • Get approval for lifting
SWL plan
• Prepare packing & skids

• Prepare lifting equipment

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Module 4 – Planning and Execution of Lifting Operations
Execution Overview | 36

• Do test lift above the

• Attached tag line to guide
ground
load
• Check for overload alarm
• Attached correctly slings’
angle Lift load
• Protect slings at sharp • Guide load with tag line
corner • Check for obstacles
• Do not shock load slings
• Do not stand under load
• Use competent rigger • Do not ride on load
• One signalman
Lay down load
• Before start of job, • Lay down in clear area
recheck crane, slings, • Lay down equipment on
lifting point, etc. skids or
• Check wind condition wooden block
• Do not drag from under
the load
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Module 4 – Planning and Execution of Lifting Operations
Execution Overview | 37

Lifting heights and

radius

Use tag lines

Line crane hook

Inform deck crew

Plan your lift

Maintain eye contact

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Module 5 – Lifting Equipment

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Module 5 – Lifting Equipment
Components of Lifting Equipment
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 Lifting Equipment comprises of:

a) Lifting Appliances (equipment performing the lifting)

b) Lifting Accessories (devices which connect the load to the

Lifting Appliance)

c) Lifted Equipment
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Module 5 – Lifting Equipment
Components of Lifting Equipment
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Module 5 – Lifting Equipment
Lifting Accessories
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 Wire rope

 Shackle

 Webbing sling

 Container

 Chain block, lever hoist and tirfor

 Hook

 Eyebolts

 Snatch block

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Module 5 – Lifting Equipment
Wire Rope – Construction of Wire Rope
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3/4 - 6 x 19 - FC
5/8 - 6 x 37 - IWRC 42
Module 5 – Lifting Equipment
Wire Rope – Construction of Wire Rope
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Wire in 1 strand
Strand

Core

FC - Fiber Core
IWRC - Independent Wire Rope Core
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Module 5 – Lifting Equipment
Wire Rope – Construction of Wire Rope
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Ferrule

• SWL (safe working load)

• Serial Number
• Date Manufactured
• Color Code
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Module 5 – Lifting Equipment
Wire Rope – Safe Working Load | 45

• Specified Breaking Strength

• Safety Factor

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Module 5 – Lifting Equipment
Wire Rope – Wire Rope Fitting & Termination
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Wedge Socket Thimble with Ferrule

Close Socket Pressed Sleeve

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 Module 5 – Lifting Equipment
Wire Rope – Defects of Wire Rope Sling
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• Kinking is caused by Loops that have been drawn too tightly as a

result of improper handling
• Kinks are permanent and will require that the rope, or damaged
section, be taken out of service

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Module 5 – Lifting Equipment
Wire Rope – Defects of Wire Rope Sling
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• Bird caging is caused by the rope being twisted or by a sudden

release of an overload
• The rope, or the affected section, must be replace

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Module 5 – Lifting Equipment
Wire Rope – Defects of Wire Rope Sling
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• Corrosion is often due to: • Core protrusion can be caused by

Inadequate lubricant shock loads and/or torsional
Improper type of lubricant imbalance
Improper storage • This condition requires that the rope
Exposure to acids be taken out of service

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Module 5 – Lifting Equipment
Wire Rope – Defects of Wire Rope Sling
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• This is often the result of heavy loads over small sheaves. These
breaks being caused by strand nicking resulting from the heavy
loads.

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Module 5 – Lifting Equipment
Wire Rope – Good Storage System | 51

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Module 5 – Lifting Equipment
Wire Rope – Care and Maintenance | 52

 Purpose of Lubrication

a) Initial factory lubrication will not last

 Good Lubricant Characteristics

a) Corrosion resistance

b) Water repellant

c) Penetrating ability

d) Temperature stability

 Lubricant Frequency

a) Recommended at least quarterly

b) Depending on the usage

c) Working environment
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Module 5 – Lifting Equipment | 53

Wire Rope – Pre-Use Checks

 SWL is adequate for the load

 Color coding (where applicable)

 Plate number / ID mark

 Each individual leg along its entire length – Wear, corrosion, abrasion,
mechanical, damage, broken wires

 Ferrule should be free from cracks or other deformities

 Examine master link assembly (wear, corrosion, cracking)

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Module 5 – Lifting Equipment | 54

Shackle – Types of Shackle

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Module 5 – Lifting Equipment | 55

Shackle – Parts of Shackle

Crown

Pin

Jaw 55
Module 5 – Lifting Equipment | 56

Shackle – Defects of Shackle

Wrong Pin Overload

Jaw Opening Gouging / Cut Marks56

Module 5 – Lifting Equipment | 57

Shackle – Pre-Use Checks

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Module 5 – Lifting Equipment | 58

Shackle – Unsafe Practices

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Module 5 – Lifting Equipment | 59

Shackle – Good Storage System

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Module 5 – Lifting Equipment | 60

Webbing Sling – Types of Webbing Sling

Flat webbing slings Round webbing slings

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Module 5 – Lifting Equipment | 61

Webbing Sling – S.W.L/Safety Factors

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Module 5 – Lifting Equipment | 62

Webbing Sling – Defects of Webbing Sling

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Module 5 – Lifting Equipment | 63

Webbing Sling – Pre-Use Checks

 SWL is adequate for the load

 Color coding (where applicable)

 Plat number / ID mark

 Cuts, tears or chafing

 Burst stitching (especially round the eyes)

 Chemical damage

 Ingress of foreign bodies into the fibers

 Distortion / wear in the metal eyes (where fitted)

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Module 5 – Lifting Equipment | 64

Webbing Sling – Good Storage System

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Module 5 – Lifting Equipment | 65

Container – Types of Container

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Module 5 – Lifting Equipment | 66

Container – Markings on Container

• Company name
• Size
• Date inspection
• Next inspection
• Content
• TW - Tare weight (weight of empty
container)
• SWL - Safe Working Load (the content)
• MGW - Maximum Gross Weight (total
weight)

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Module 5 – Lifting Equipment | 67

Container – Markings on Container

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Module 5 – Lifting Equipment | 68

Container – Pre-Slungs

Dedicated slings and shackles

DO NOT REMOVE!!

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Module 5 – Lifting Equipment | 69

Chain Block - Functions

• Chain block is main for lifting

• Safety latches must be fitted on the hook

• Design for one person to pull

• Do not overload

• No suspended load

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Module 5 – Lifting Equipment
Level Hoist - Functions | 70

• Lifting devices operated with a handle

instead of hand chain

• Not available in very high capacities (not

more than few tons)

• Short load chain

• Used for short lifts

• Commonly abused (attempt to get more

leverage by extending the

handle with a piece of pipe)

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Module 5 – Lifting Equipment | 71

Level Hoist - Tirfor

• Main for pulling

• Can also be used for lifting, but less capacity
• Do not overload by using an extension pipe 71
Module 5 – Lifting Equipment | 72

Chain Block - Pre-Use Checks

• Safe working load is adequate for the load

• Color coding is current (where applicable)

• Safety latches are fitted

• No sign of misuse

a) Stretched hook

b) Corroded casing

c) Stretched/distorted chain.....etc.

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Module 5 – Lifting Equipment
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Chain Block - Defects of Chain

Welded Chain Gouges cuts cracks

Knot in chain Corroded chain

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Module 5 – Lifting Equipment | 74

Hooks – Types of Hooks

Celvis Hook Eye Hook Swivel Hook Grab Hook

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Module 5 – Lifting Equipment | 75

Hooks - Parts of Hook

Throat Eye

Body

Saddle

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Module 5 – Lifting Equipment | 76

Hooks – Defects of Hook

• Throat Opening • Hooks Modification

• Twisting of Hook Body • Crack/Wear at Saddle

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Module 5 – Lifting Equipment | 77

Hooks – Pre-Use Checks

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Module 5 – Lifting Equipment | 78

Eyebolts – Types of Eyebolts

Dynamo Collar Collar with link

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Module 5 – Lifting Equipment | 79

Correct Use of Eyebolts

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Module 5 – Lifting Equipment
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Correct Use of Eyebolts

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Module 5 – Lifting Equipment | 81

Correct Use of Eyebolts

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Module 5 – Lifting Equipment | 82

Eyebolts – Types of Eyebolts

Eye

Body

Thread

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Module 5 – Lifting Equipment | 83

Snatch Block – Types of Snatch Block

Single Sheave Block

Function to increase pull force

Multi Sheave Block

Function to reduce pull force

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 Module 5 – Lifting Equipment | 84

Snatch Block – Pre-Use Checks

Examine head fitting shackle/eye

The SWL is adequate for
The load

The color coding is current

Ensure all grease
ports are clean &
unblocked

Examine sheave Spin the sheave to check

for wear or crack bearing/bushes

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Module 5 – Lifting Equipment | 85

Snatch Block – Inspection

 Side plate securing bolt cannot be fully withdrawn

 Manufacturer's certificate & certificate of application

 Maintenance / inspection shall be according to manufacturers’

recommendation

 Ensure split pins, locking and secure pins are in place

 Ensure support structure is of adequate strength

 Consider total resultant forces acting supporting structure

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Module 6 – Rigging Principles and Terminologies

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Module 6 – Rigging Principles and Terminology | 87

Terminology

Term Description
Working Load Limit Stated capacity of lifting equipment
(WLL)
Safe Working Load The load the equipment can safely lift
(SWL)
Breaking Strength (BS) The actual force required to pull rigging
gear to destruction
Proof Loading Proof loaded by a certified body
acceptable by relevant authority
Safety factors To calculate the WLL/SWL of different
types of lifting equipment.
Tare weight (TW) Weight of empty container
Maximum Gross Weight Total weight MGW = TW + SWL
(MGW)
Included Angle Angle created between the sling legs
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Module 6 – Rigging Principles and Terminology | 88

Centre of Balance

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Module 7 – Communication

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Module 7 – Communication
Roles of Banks man | 90

 Proper rigging of load

 Supervision of the rigging crew

 Ensuring that the rigging material & equipment have the necessary
capacity & in safe condition

 Ensuring correct assembly of rigging material or equipment

 Safety of the rigging crew and other personnel

 Correct signaling during the lifting operation

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Module 7 – Communication
Who are Qualified to be Banks man? | 91

 Supervisor

 Foreman

 Team Leaders

 Bosun

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Module 7 – Communication | 92

Hand Signals

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Module 7 – Communication
| 93
Hand Signals

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Module 7 – Communication | 94

Hand Signals

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Module 7 – Communication | 95

Walkie Talkie

Advantage Disadvantage
• Provide accuracy of crane • Communication break down
movement due to:
• Confident to carry out the  Garble message
operation  Weak battery
• Commonly use for lifting at  Wave interference
height / blind spot & night  Interruption
activities  Background noise

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Module 8 – Awareness of Lifting Operation

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Module 8 – Awareness of Lifting Operation | 97

Crane Operating Principles – Centre of Gravity

• Centre of gravity is the point around which an object’s weight is

evenly balanced

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Module 8 – Awareness of Lifting Operation | 98

Crane Operating Principles – Leverage Cranes

• Principle to lift load. Rotation of the upper works changes the

location of the crane’s centre of gravity & leverage point

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Module 8 – Awareness of Lifting Operation | 99

Crane Operating Principles – Stability

• Relationship of the load weight, angle of boom and its radius to
the centre of gravity of the load

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Module 8 – Awareness of Lifting Operation | 100

Crane Operating Principles – Structural Integrity

• The crane main frame, boom sections & attachments are all
considered part of the structural integrity of lifting

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Module 8 – Awareness of Lifting Operation | 101

Crane Operating Principles – Conflicting Activities

 Lift Plan

 Location

 Nature of activities

 Hazard

 PTW

 Toolbox talk

 Communication

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Module 8 – Awareness of Lifting Operation | 102

Crane Operating Principles – Conflicting Activities

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Module 8 – Awareness of Lifting Operation | 103

Crane Operating Principles – Environment

Factors
 Internal spaces of vessels and rigs

 Transferring equipment from vessels & platforms

 Moving equipment around the deck at sea

 Submerging or recovering equipment in the sea

 Vessel motion and stability

 Weather, wind and sea forces

 Seabed suction and dynamic loading

 Noise, light, spray

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Module 8 – Awareness of Lifting Operation | 104

Manual Handling

Size up the load Get another to help if the load is

heavy

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Module 8 – Awareness of Lifting Operation | 105

Manual Handling

Make sure your footing is Do not lift objects that

secure obscure vision & footing

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Module 8 – Awareness of Lifting Operation | 106

Manual Handling

Lift smoothly and Alternate lifting tasks

slowly. Do not jerk! with lighter work

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Module 8 – Awareness of Lifting Operation | 107

Manual Handling

Do not twist while lifting Try to avoid carrying a load

more than 10 feet without
mechanical assistance
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Module 8 – Awareness of Lifting Operation | 108

Manual Handling

Get as close to the load as Avoid lifting from the floor

possible or above shoulder level

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Module 8 – Awareness of Lifting Operation
Manual Handling | 109

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Module 8 – Awareness of Lifting Operation | 110

Manual Handling

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Module 8 – Awareness of Lifting Operation | 111

Appreciation of Dynamic Factors

 A "STATIC" load on a crane means that the effect of the load on

the machine never become greater than the weight of the load

 A "DYNAMIC" load is one where the effect of the load on the

crane is MORE than the actual weight of the load

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Written Assessment

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Any Question
Thank you

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