Mammoet & LEEA Rigging and Planning Manual
Mammoet & LEEA Rigging and Planning Manual
And
Planning
Manual
0
Contents
Forward i
Basic Mathematics ii
Weight calculations Section 1
Safe working loads calculations Section 2
Trigonometry Section 3
Centre of gravity calculation – Composite objects Section 4
Centre of gravity calculation – Non-symmetrical Section 5
Sling calculations – Non-symmetrical bridle Section 6
Equalizer beam calculations Section 7
Lifting in water calculations Section 8
Wind Calculations Section 9
Support system (mats) calculation Section 10
Crawler crane imposed loading calculations Section 11
Multi Crane Lifts (Tandam Lifting) Section 12
Multi crane lifts – Head and tail weights Section 13
Risk Assessments Section 14
Legislation and ACOPs Section 15
Types of Lifts in regards to lifting operations Section 16
Selection of Personnel Section 17
The management of lifting operations Section 18
The Planning of Lifting operations Section 19
Method Statements Section 20
Hook Block Calculations Section 21
Glossary Section 22
Index Section 23
This workbook is for guidance only. It and Mammoet Holding BV cannot be held
responsible for any inaccuracy.
1
Forward
Since the first crane was used to lift water and building blocks for the
great pyramids by the Egyptians and Leonardo de Vinci innovated
cranes to help build some of the most fabulous cathedrals in Europe,
some one, somewhere had to take charge, supervise and plan these
lifts.
With the intervention of the 21st century with cranes that are bigger,
taller and stronger. There are more than ever the presents of a
supervisor and planner. Whose sole responsibility is to ensure that the
lifting operation goes to plan?
We believe many people have had an input into this book, and also
from other sources and we are grateful for there help in devising such a
prolific read and study aid
With this in mind this book is a must for crane operators, supervisors
and appointed persons, and important source of knowledge for riggers
and other people who depend on mobile cranes for there day to day
operations.
2
Basic Mathematics
+ Plus
- Minus
X Multiply
÷ Divide
% Percentage
. Decimal point
: Ratio
∏ Pi, or 3.14 or 22/7
If you are required to change a fraction into decimals divide top into the
bottom
Example
5/8 = .625
L x B = m2
Example
Area of a circle
∏r2 or
3.14 x diam x diam ÷ 4
Example
3.14x2mx2m = 12.56m²
3
3.14 x 4mx4m ÷4 = 12.56m²
Weight Calculations
Oil 800
Magnesium 1750
Concrete 2440
Brickwork 2000
Water 1000
Steel 7700
Cast Iron 7200
Aluminium 2700
Earth 1600
Paper 1120
Copper 8800
Lead 11200
Soft Wood 600
Hard Wood 800
Greenheart 1200
NOTE: The figures above represent an average weight which has been
rounded for ease of use. Figures may possibly change due to water
content and composition.
4
5
Safe working loads calculations
The new combined S.W.L could affect the load weight to be lifted.
For Example:
5te 5te
10te
Example:
5te 5te
90º
7te
6
The reason for this is the relation of the S.W.L of the lifting accessories
and the angle between the slings
30º
0.53te
60º
0.58te
0.7te
90º
1te
120º
Fig14
Load weight of 1te
Fig 14
The relation between angle and the force applied to the sling is
constant through out the lifting operation. The greater the angle the
more force applied to sling therefore it is of importance that you do not
exceed the recommended maximum sling angle of 90º
7
Example
To find out what S.W.L our lifting accessories are now rated at. We take
the safe working load of one accessory if they are all compactable in
S.W.L or the lowest S.W.L if different lifting accessories are being used.
Formula
Therefore using our chart (fig 14) we find our force-loading equal to our
angle being used for this example of 90º it is equal to 0.7te per leg
because we will be using 2 round slings the total force loading is equal
to 1.4te.
Formula
The answer is now incorrect. This would mean that you could use a
sling with a lower capacity this could be a contributing failing in the
lifting operation.
8
But we do not always have the ability to lift an object on two points so
therefore three or four could be used.
The formula follows the same format as before the only figure that will
require changing is our force loading.
The principle of the force loading is the multiplying of the force relevant
to the amount of legs in use.
2.1te
The reason for the similarity in three and four legs is because of equal
weight distribution on each leg and so in these calculations we cannot
guarantee that the weight will be symmetrical throughout the lifting
operations.
The formula for calculating with three and four legs it would be as
followed.
Still using our 5te round slings and working at 90º the new combined
S.W.L will be
9
It is also important to remember when pairing 2-legged chain in order
to carry out a lifting operation. Before we start our operation we must
check all factors the first is compatibility of our lifting accessories and
also that 2 legged chains are rated at a 2 dimensional angle when
paired up a facilitating a 4 point lift you have a 3 dimensional angle but
only 2 dimensional lifting accessories.
To find our new S.W.L we multiply the S.W.L by a mode factor of 1.5
Example:
10
Trigonometry
a
b
A B
The three angles of a triangle always total 180 degrees. If two of the
variables are known, side lengths or angles, the remaining side lengths
and angles can always be calculated.
Sine B = cosine C
Sine C = cosine B
Tangent B = cotangent C
Tangent C = cotangent B
11
Sides and/or Angles
Formula for sides and angles to be found
Known
b
a and b C = √ a² - b² Sin B = a C = 90º - B
c
a and c
B = √ a² - c² Sin C = a B = 90º - C
b
b and c
A = √ b² + c² Tan B = c C = 90º - B
C = 90º - B
a and B b = a x Sin B c = a x Cos B
a and C b = a x Cos C c = a x Sin C B = 90º - C
a= b
b and B c = b x cot B C = 90º - B
Sin B
A= b
b and C c = b x Tan C B = 90º - C
Cos C
a= c
c and B c = c x Tan B C = 90º - B
Cos B
a= c
c and C Sin C b = c x Cot C B = 90º - C
Sine = Opposite
Hypotenuse
Cosine = Adjacent
Hypotenuse
Tangent = Opposite
Adjacent
12
Example
Finding the hook and lifting point’s angles for the following:
6.2m
4.8m
13
Example Cont:
Refer to the natural sines table: look for a number equal to or less than
0.3609 = 0.3600
Read the degrees of the angle in the left-hand column this = 21º. Then
read the minutes of the angle from the top of the 0.3600 column =6’.
The difference between 0.3609 and 0.3600 = 0.0009 ignore the zeros
and look for a figure in the right hand column as near to or greater than
9 =11
14
Centre of gravity calculations – Composite objects
Example:
Datum
4. Identify the distance from the datum to the centre of each part.
L3
L2
L1
Formula:
Example:
15
L3
L2
L1
Therefore L1 = 7m
L2 = 36m
L3 = 60m
Ans = 21 + 72 + 120
7
16
= New centre line of lift
Example:
Therefore the new centre line of lift is directly over this point the new combined
CofG
17
Sling Calculations
Non-Symmetrical Bridle
T2
SLING B H2
L2
SLING A
H1 D2
L1
D1
13.6te
T1
Formula:
Sling A = load x D2 x L1
D2 x H1 + D1 x H2=
= 208
18.5
=11.3te
Sling B = load x D1 x L2
D2 x H1 + D1 X H2
= 167
18.5
=9te
18
Equaliser Beams Calculations
To ensure that the lifting operations using a equaliser beam is carried out
safely and using two crane we must ensure that, the total capacity of the cranes
must be at least equal to or more than the total weight to be lifted including the
load, lifting beams, rigging, hooks and attachments.
B C
For Example
19
Cont:
= C x (W + Rigging) + ½ beam
A
= B x (W + Rigging) + ½ beam
A
Example
1.451te
B C
A 4.572m
CRANE 1 CRANE 2
113.3981te 58.96701t
Ans = 1.619m
20
This is the lift point of the load on the beam
1.451te
205kg
Wt
158.757te
1.619m 3.133m
4.752m
= 104.956te
21
Load on hook on crane 2
=54.310te
22
Lifting in and out of Water
23
In water load on hook
Example
Weight of block
Ans = 7.68te
A Concrete block
Ans =3.23te
24
Wind Calculations
The wind speed restrictions within lifting operations are a factor that is
overlooked. The wind is an everyday factor that cannot be controlled
but can be managed by proper planning. A majority of cranes have
anemometer and a maximum permissible wind speed for lifting using
this information and calculations we can obtain a more accurate
reading or a permissible wind load.
A set value of 1m² per tonne (10.8ft²/lbs = 1m²/t). If the value of (cf) is
above 1.2 and wind surface, which are larger than 1m² per tonne of the
lifting capacity, the wind surface of the load must be reduced
proportionally. All concerned within the lifting operation must agree this.
Formula
Vred = V. √ 1.2
Cf. A
Example
14m/s x √ 1.2
1.5 x 15m² (act load area) = 1.2
10t (act load weight) 2.25
25
Due to the adverse ground conditions that can occur on site at a lifting
operation. A priority is for the crane to be supported fully through out
the entire operation.
The imposed loading relating to the lifting appliances are available from
computer programs from manufactures or from crane hire companies
that you have hired the machine from.
26
Imposed loadings = ground bearing pressure (GBP)
Area of mat used
The support system can be made from concrete pad (also reinforced),
timber mats, proprietary mats, steel grillage and piled foundations.
To make the correct assessment first of all we must obtain the right
information this would first of all the imposed loadings the crane
creates. This can be obtained from the crane hire company and is
freely available or can be calculated using relevant formulas.
See fig15 and fig 16 these are example of information that can be
resourced by the person planning the lifting operation (Appointed
Person). The other information required is the construction of ground
where the crane is going to be position during the lifting operation; this
can be sourced at other location and other geological reference books.
Fig 15
27
Fig 16
28
Fig 17 Site investigation report
29
Reduced Depth Samples / Test
Description / Face Legend Field Records
level (Thick) Depth Type No Test
Tarmacadam 9.3 9.25 (0.05) 0.20 D 1
0.05
30
MADE GROUND: Brown slighty
clayey very sandy gravel with
occasional half to full bricks
present. Gravel is subangular and
(0.65)
subrounded fine to coarse brick,
ash, tarmacadam and concrete.
Occasional coble sized fragments
of tarmac from 0.8m
8.60 0.70
0.80 D 2
MADE GROUND: Dark browm
slightly clayey to locally clayey
slightly gravelly fine to coarse (0.50)
sand. Gravel is subanggular and
subrounded fine to coarse brick,
ash, tarmacdam and concrete
8.10 1.20
MADE GROUND: (Soft) dark
grey sandy organic clay with
(0.40)
occasional rootlets (diameter >
1.50 D 3
5mm). Gravel is subangular fine
to coarse brick and sandstone
7.70 1.60
MADE GROUND: Brown slightly
gravelly fine to coarse sand.
(0.60)
Gravel is subangular fine to
2.00 D 4
coarse brick, concrete and flint
7.10 2.20
5.60 3.70
GRANULAR COHESIVE
31
300mm
32
Further information on site investigation practice can be obtained
from standard publications.
33
FOS = 3.0 used where minimum ground information available
FOS = 2.0 Most site and ground conditions
Now that all the relevant information has been collated we then can
determine the size of our support system or type.
34
For Example
If the ground bearing pressure is 30tem² and the outrigger loadings for
a crane is 216tem² the two sets do not match and therefore an accident
is inevitable to happen.
216te = 28.80tem²
7.5m²
Once you have sourced the information from all parties i.e the crane
manufacture, hirer and the principal contractor you the can calculate a
support system that is required for the lifting operation, it is important to
remember when a multi crane lift and the cranes in close proximity the
possibility of a higher imposed loading.
36
37
Multi Crane Lifts (Tandem Lifting)
The safety factor (%) can vary due to condition of lift also environment
which the lifting operation is taking place i.e. petrol-chemical site. The
basic value is 20% but can be more. This helps to take into account
any tendency for ropes to be slightly out of vertical during the lift, or any
dynamic loadings.
38
Multi Crane Lifts – Head & Tail Weight Calculations
(Fig 1)
39
40
Multi Crane Lifts – Head & Tail Weight Calculations
(Fig 2)
Example:
Head Tail
L3
L1 L2
= Calculated CofG
Formula:
Tail weight of the load =
Tail = L1 x Wt
L3
Example:
3.25m 11.50m
41
Example Cont.
= 211.25
14.75m
Ans = 14.32te
Ans = 747.5
14.75m
Ans = 50.68te
42
RISK ASSESSMENTS
Very Unlikely
A freak combination of LOW
factors would be LOW LOW LOW MEDIUM
required for an
accident/incident to
result.
Unlikely
A rare combination of LOW
factors would be LOW LOW MEDIUM MEDIUM
required for an
accident/incident to
result.
Possible
Could happen when LOW
additional factors are LOW MEDIUM MEDIUM HIGH
presented but
otherwise unlikely to
occur.
Likely
Not certain to happen LOW
but an additional factor MEDIUM MEDIUM HIGH HIGH
may result in an
accident/incident.
Very Likely
Almost inevitable that MEDIUM
an accident/incident MEDIUM HIGH HIGH HIGH
would result.
43
RISK EVALUATION
Likelihood of occurrence (L) = How often could the hazard occur? Consider the
task frequency, duration, method of work, employees involved.
Hazard Severity (S) = How serious would the hazards effect be if realised.
Consider the type of hazard, biological, ergonomic, physical and chemical.
To evaluate the likelihood and severity will produce a Risk Rating (R).
The Risk Assessment Matrix provides guidance in determining the risk ratting.
Therefore, if the likelihood of occurrence is possible and the hazard severity is
given as moderate, then the risk rating would be medium.
44
A common list of
(b)Appropriately supervised:
45
Types of lifts in regards to lifting operations
1) Basic Lift:
Note: Always allow for inaccuracies when calculating the weight of the
load.
46
(d)Ensue a reporting system is in place for both appliances and
accessories.
Note: The appointed person and the crane supervisor should be aware
of the limits of their knowledge and experience concerning lifting
operations and should understand when to seek further advice.
2) Standard Lift
The standard lift is normally coincide with the lifting of persons but
however some aspect must be adhered to in order to complete the
appropriate planning to allow this type of lift to go ahead.
If there are hazards, either within the working area of the crane or the
access and egress route to the working area.
Standard lift does not cover multi crane lift. The person planning the lift
should take into consideration all aspects covered in the basic lift and
in addition the following:
(a)Invest all hazards within the lifting operation area; these could
include the area for erection and dismantling of the crane. This
may come in the form of crawler crane erection and
47
dismantling or mobile crane fly jib erection or dismantling or a
small luffing fly jib.
(b) Take into account the increased risk involved if the load is
being lifted from a structure, which is at a height above the
cranes set up position.
Note: Other risks may arise if the crane operator is working blind to the
lift and is preparing to inch the load. A common factor called jib
deflection may arise causing:
i) Overload due to an increase of radius
ii) The load not to be lift level or plum
iii) The load can be lifted but cannot be lowered safely or
repositioned
(d)The interface and relation your lifting operation has with the
surrounding property and or person’s including the general
public. This should coincide with current legislation and
statute.
If your lifting operation requires more than one crane to lift the load
or the cranes will be using load enhancement attachments (super lift
or maxi lift). Also if the lifting operation is taking place in a location of
exceptional hazards (e.g. at a petrochemical plant) the person
planning the lifting should take into account all the information and
detail, required for the basic lift and standard lift but in addition the
information listed below:
48
(a)The weight of the load is known.
(b)The lifting points provided on the load are strong enough for
the loads applied.
Now that we have a understanding of the three types of lift that can
be carried out and what detail is required then the next step is to see
how we you are going to carry out your lifting operation
49
Selection of personnel
50
He or she is responsible for ensuring that the safe system of
work is communicated to all personnel involved, usually done
by the method statement.
Note: The Appointed person may delegate the task of, or a task from
the lifting operations but not the responsibility.
Note: The appointed person does not have to be on site but the
appointed person for that lift must carry out any changes to the lifting
operation.
51
Note: If the crane supervisor is also a crane driver, then he or she
should not operate any crane involved in the lifting operation but
supervise.
Note: The appointed person may decide to undertake the duties of the
crane supervisor or delegate the duties to another person with
appropriate expertise for the lifting operation.
52
The Management of lifting operations
i. Risk assessments.
ii. Planning of the lifting operation.
iii. Preparation of a method statement.
iv. Selection, provision and use of a suitable lifting appliance
and equipment.
v. Preparation of the site (If required).
vi. Provision of properly trained and competent personnel.
vii. Supervision carried out by properly trained and competent
personnel with authority
viii. Ensuring that all test certificates and any other relevant
documents are available.
ix. Preventing the unauthorised use and movement of the
lifting appliances.
x. The consideration of personnel not involved in the lifting
operation.
Also the appointed person may have other duties and is not
necessarily a direct employee of the employing organisation.
53
The planning of a lifting operation
(f) The load characteristics and the method in which the load
or item is to be lifted.
(i) The position of the crane(s) and the load before and during
and after the lifting operation.
(j) The site for the lifting operation and the areas of concern
for example proximity hazards, space and the suitability of
the ground or foundations.
Note: For routine lifting operations an initial lift plan may only be
required once but there is a need to review it occasionally to make sure
that nothing has changed and the lift plan remains valid.
For more complex lifting operations you need to plan the task each
time it is carried out.
Method Statements
54
When producing your method statement remember how and who is
going to communicate to the lifting operation team, also in some cases
the method statement could have been written several months before
the lifting operation is to take place
Depending on the nature of the lifting operation will have an effect on
the context of your method statement the diverse (complex) the lifting
operation the more information attained in your method statement? The
more routine (basic) the lifting operation the reduced amount of
information required.
55
Common Hand Signal
56
Basic Crane Sizing Chart
57
58
Lifting Accessories Charts
1 2 3 4 5 6 7 8 9
Material Single Single Single leg Single Single leg Endless Endless Endless
leg le bask leg halsh in choke basket
in g et bac ed line d 0-90o
lin ch k
e ok hoo
ed ked
Flat Web
Accessorie
s and
Round
Slings
59
Calculation of the required hook block weight
It is important that when carrying out lifting operations the correct hook
block is used, not only in size, shape and capacity but it self weight.
The reason behind this is to maintain tension on our hoisting line and to
not to exceed our parameters set with in our load charts or duty charts.
Formula
G=LxMxNxF
Table 1
60
Table 2
Or our last resort would be the load chart book or even the
manufactures marketing brochure and operator’s manual.
61
The example we are going to use using the drawing above.
62
Example
Therefore the hook block weight we would require is 7244kg or 7.2 te.
However some crawler cranes are able to reeved up with 2 hoist lines
on 1 hook block, in order for to achieve the correct weight we also have
calculate using the same formula but with additional information.
Example
G=2xLxMxNxF
63
Index
A
A.C.O.Ps 44
Appointed Person 49,50
B
Basic Lift 45,46
Basic Mathematics 3
Basic sizing chart 56
C
Calculating Area 3
Centre of Gravity composite 15,16
Centre of Gravity Non-symmetrical 17
Complex Lift 47, 48
Crane Supervisor 50,51
Crawler Crane imposed loading 35
Crawler Crane loading (fig 20) 36
E
Equaliser Beam Calculations 20,21,22,23
External Triangle rule of thumb 57
F
Forward 2
G
Glossary 63
H
Hand Signals 55
Head and Tail weight calculations 40,41
64
K
L
Legislation 44
Lifting Accessories Chart 56
Lifting In and Out of Water 24,25
LICCON Planner (fig 16) 30
M
Management of Lifting Operations 52
Method Statements 53,54
Multi Crane Lift 37,38,39
N
Non-symmetrical Bridle 18,19
O
Outrigger Loading (fig 15) 29
P
Planning of Lifting Operations 53
R
Risk Assessments 42,43
S
Safe Working Load 6,7,8,9,10
Sin Table 12
Sin Calculation 13,14
Site Investigation Report (fig 17) 31
Soil Description (fig 18,19) 32,33
Standard Lift 46
Support System 27,28,34
T
Tandem Lifting 37,38,39
Trigonometry 11
U
Uniform loading 7
65
V
Volume Formulas 5
W
Weight Calculations 4
Wind Calculations 26
66