Rigging Safety: Guide
Rigging Safety: Guide
Rigging Safety: Guide
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RIGGING SAFETY
GUIDE
Proper R igging for Mechanical Construc tion and Ser vice
RIGGING SAFETY GUIDE
Forward
This guide is intended to help the user include safety in the planning and actual practice
of rigging mechanical industry equipment and materials for lifting operations.
RIGGING SAFETY GUIDE
Introduction
The three main parts to any load lifting operation are the lifting equipment (crane/derrick/
hoist), the operator/operation of the equipment, and the rigging of the load. This guide
focuses on the rigging of the load. Specifically, it addresses how mechanical construction
and service workers can safely rig the types of loads that are most common in our
industry.
This guide does not cover all there is to know about rigging. While most mechanical
construction and service workers are not rigging experts, many of them become skilled at
safely rigging the materials and equipment used in the mechanical industry.
Ten basic rules for safe mechanical industry rigging operations are described in this
guide. By learning the basic concepts behind each rule and following the rules while
participating in mechanical industry rigging operations, mechanical industry riggers will
help keep themselves and others in the work area safe from rigging related hazards.
Basic rigging safety for routine lifts in mechanical construction and service industry
applications are covered in this guide. Critical lifts are not routine lifts and require
considerable professional expertise in lifting equipment, operation of the equipment,
rigging, and critical lift planning. Critical lifts may include, but are not necessarily
limited to lifts involving multiple cranes, lifts over operating facilities, lifts close to
power lines, lifts that exceed the designated percentage of the rated capacity (usually
between 70% and 80%), lifts over occupied buildings, etc. Before participating in the
rigging of a critical lift make sure that:
• A critical lift plan designed specifically for the critical lift that you will be
involved with has been developed by a properly trained/qualified person;
• The most senior supervisor in charge of the lift, the equipment operator and the
lead rigger have approved and signed off on the critical lift plan; and
• Your supervisor has verified that you are properly trained and qualified to
participate in the critical-lift rigging process.
This guide is not intended to provide exhaustive treatment on the subject of crane,
derrick and/or hoist rigging operations as they pertain to the mechanical construction
and service industry. Further, it is not intended to provide legal advice. Employers
must make independent determinations regarding the need for legal assistance.
The rated capacities of cranes/derricks/hoists and rigging equipment are of little practical use if
you do not know the weight of the load that is to be rigged and lifted. In some cases it will be
rather obvious that the load is too light to exceed lifting and rigging equipment- rated capacities.
However, there will be cases when you are uncertain whether the load can be lifted safely. That
is when you need to establish the weight of the load and compare it to the rated capacities of the
lifting equipment, sling or slings, and rigging hardware. Here is how to determine the weight of
the materials most commonly rigged for lifting in the mechanical industry.
Pipe
Pipe weights are standardized by material and wall thickness. Manufacturers often paint the
weight per foot on the pipe making weight calculations simple. You can also use pipe charts
when they are available, but when necessary, calculate the weight of steel pipe by using the
formula below. If there are multiple pieces of the same size and type of pipe, remember to
multiply the weight of one piece by the total number of pieces. For various sizes/types of pipe,
calculate the weight of each piece and add them together.
In the following example, we will calculate the weight of a single piece of steel pipe.
Weight of Steel Pipe = Pi x D x L x T x (Unit Weight)
Key What It Means Illustration
Pi 3.14
D 3 feet
L 20 feet
T .03125 feet (.375 inches divided by 12)
Unit Weight 189.57 pounds/foot
Using the formula and numbers above, we determine that this piece of pipe weighs 1,116 pounds
(3.14 x 3’ x 20’ x .03125’ x 189.57 = 1,116).
A rigging hitch is used to attach the sling to the load. There are three basic types of hitches: the
vertical hitch, choker hitch, and basket hitch. It is critical that the hitch you select will safely
support the load.
For example, a single choker hitch would not provide full support for a stack of loose pipe.
When the lift starts and the sling tightens, it would become taut around the bottom and sides of
the stack, but the pipe on top of the stack would remain loose. A much safer choice for a stack of
loose pipe would be a 2-sling double wrap choker hitch or a 2-sling double wrap basket hitch,
which would secure the pipe for lifting.
The illustrations on the following pages show the proper applications for hitches that are
commonly used in our industry.
4 Slings/Shackles
One of the most important things to remember about sling tension is that the lower the angle
between the load and the sling, the higher the tension on the sling. Angles also increase the
tension on hardware. Hardware’s rated capacity decreases when it is pulled from any direction
other than vertical. This is critical information for proper sling and hardware selection and proper
use.
H: 19.36’
Hardware Examples
Continuous reduction in percentage of rated Continuous reduction in percentage of rated capacity
capacity as the angle increases. Check with the as the angle is increased and load moves out from
manufacturer for details. center of hook.
100% of Rated Capacity 100% of Rated
Capacity
3-Leg Slings Share the Whole Load 4-Leg Slings: 2 Legs Carry Most of the Load
There are several different types of slings to choose from. The slings used most frequently in the
mechanical industry are synthetic web slings, synthetic round slings, wire rope slings, and alloy
steel chain slings. A critical consideration in sling selection is the relationship between the rated
capacities of the sling and the type of hitch you plan to use. The rated capacity of a sling used
with a vertical hitch will be different if you use the same sling with a choker hitch or a basket
hitch. For example:
1. Is the sling compatible with the hitch you will use to perform the lift safely?
2. Does the design and composition of the sling make it strong enough to perform the work
safely (rated capacity)? Remember to consider reductions for sling angles and the type
of hitch you will be using.
6. Could the specific rigging/lifting application cause the sling to break or otherwise
become damaged during the lift?
Rated capacity.
Protection from sharp edges.
Strength largely depends on the size of the
sling.
Great for temporary work such as
mechanical construction and service work.
PROS
• Forms easily to the shape of the load.
• Provides a non-slip grip on the load.
• Less likely to damage delicate loads such as HVAC units.
• Less likely to scratch loads with polished surfaces such as HVAC units.
• Can absorb a lot of shock without being damaged.
• Rated capacity is unaffected by abnormally hot air temperatures.
• Unaffected by mildew.
• Resistant to some chemicals.
• Long service life.
Rated capacity.
Protection from sharp edges.
Strength largely depends on the size of the
sling.
PROS
• Forms easily to the shape of the load.
• Unlikely to damage delicate loads such as HVAC units.
• Unlikely to scratch loads with polished surfaces such as HVAC units.
• Rated capacity is unaffected by abnormally hot air temperatures.
• Unaffected my mildew.
• Resistant to some chemicals.
• Long service life.
CONS
• Can burn from exposure to acids or caustics.
• Can melt or char from contact with flames/extremely hot heat sources.
• Susceptible to cuts from sharp objects.
• Exposure and/or damage to core yarns render these slings ineffective/defective.
PROS
• With Wire Rope Core - Tend to be strong and somewhat resistant to heat.
• With Fiber Core – Tend to be flexible.
CONS
• With Fiber Core – somewhat vulnerable to environmental conditions.
• Subject to kinking, which weakens wire rope.
• Subject to tiny cracks from small radius bends, which weakens wire rope.
• Wire rope made with smaller wires is more susceptible to abrasive wear.
Rated capacity.
Rigging/lifting conditions.
Type of load to be rigged/lifted.
PROS
• Strong and durable.
• Perform very well in harsh environments.
Selecting the right hardware for each specific rigging application is just as important as selecting
the right slings. Hooks, shackles, eyebolts, and U-bolt wire rope clips are among the most
frequently used rigging hardware in our industry. While there are several different types of
hardware in these categories, the selection process is the same for hooks, shackles and eyebolts.
They are rated based on straight, linear tension. Be aware that the rated capacity changes when
angles are involved just like it does when using slings. When selecting hardware for a particular
application ask yourself:
1. Do the design and composition of the hardware make it strong enough to perform the
work safely (rated capacity)? When asking yourself this question, remember to consider
reductions for hardware that will be used in angular situations.
General
• Capacity tables should be used only for pre-project planning purposes.
• Rated capacities of the same sizes and types of hardware may be significantly different
from one manufacturer to another. For example, the rated capacity of a 7/8” eyebolt made
by one manufacturer may be several hundred pounds different than the rated capacity for
a 7/8” eyebolt made by a different manufacturer.
• When selecting hardware, always use the rated capacity provided by the manufacturer
specifically for that piece of hardware.
• Hooks used on center (straight up and down with a balanced load) can carry 100 percent
of the rated load.
• Hooks that are off center cannot carry 100 percent of the rated load. The percentage of
the rated load a hook can safely carry depends on how far the hook is off center.
• Identification markings should be shown on each hook. If they are not shown, or if you
cannot read them, do not use the hook. Take it out of service immediately and
permanently.
Shackles
• Identification markings should be shown on each shackle. If they are not shown, or if you
cannot read them, do not use the shackle. Take it out of service immediately and
permanently.
• Identification markings should be shown on each eyebolt. If they are not shown, or if you
cannot read them, do not use the eyebolt. Take it out of service immediately and
permanently.
• Proper positioning of wire rope clips is critical to their performance. The attachment
piece that slides over both threaded ends of the U-bolt is referred to as the “Saddle.”
Remember the phrase, “Never saddle a dead horse.” That means the saddle should always
be placed over the live side of the wire rope. When you bend the rope to attach wire rope
clips, the live side is the side opposite the end of the wire rope.
• Be sure not to stagger wire rope clips. To do so, you would have to inappropriately,
“saddle a dead horse.”
• Be wary of wire rope slings made with wire rope clips. If you do not know whether the
sling has been approved for the specific application by a qualified engineer, do not use it.
Take it out of service immediately until it can be inspected by a qualified engineer.
Rigging slings wear out over time and become dangerous when they can no longer safely support
their rated capacity. Sling inspections are critical and should be performed before each use.
INSPECTIONS
• Look for permanently attached identification on each sling. The information should
include the manufacturer’s name or trademark, the manufacturer’s code number or stock
number, the rated capacities based on the three basic types of hitches, the angles on
which the capacities are based, the type of core material that makes up the sling, and the
type of cover material, if different than the core material.
• Carefully inspect synthetic web slings inch by inch to ensure that any damaged areas are
identified.
• Check for melting or charring that would indicate exposure to excessive heat or flames,
rendering the sling defective.
• Look for cuts, tears, snags or any other fiber damage, which would render the sling
defective.
• Carefully observe the stitching throughout the sling looking for broken and worn
stitching, which would render the sling defective.
Any defective sling should be destroyed immediately in accordance with your company
policy. If you find any indication that any part of a sling may be defective, or if you are not
sure, take it out of service immediately and follow the procedure for handling defective
equipment.
INSPECTIONS
• Look for permanently attached identification on each sling. The information should
include the manufacturer’s name or trademark, the manufacturer’s code number, or stock
number, the rated capacities based on the three basic types of hitches, the angles on
which the capacities are based, the type of core material that makes up the sling, and the
type of cover material if different than the core material.
• Carefully inspect synthetic round slings inch by inch to ensure that any damaged areas
are identified.
• Look for cuts, tears, snags, burns or any other signs of damage that leave the core yarns
exposed or damaged, rendering the sling defective.
• Check the sling over carefully for acid and caustic burns that would render the sling
defective.
Any defective sling should be taken out of service. If you find any indication that any part of
a sling may be defective, or if you are not sure, take it out of service immediately and follow
the procedure for handling defective equipment.
INSPECTIONS
• Look for permanently attached identification on each sling that states the size, grade,
rated capacity and the name of the manufacturer. If the identification tag is not attached,
the sling is defective.
• Carefully inspect wire rope slings inch by inch to ensure that any damaged areas are
identified.
• Look for broken wires. If there are five or more broken wires in one rope lay the sling is
defective. If there are three or more broken wires in one strand of one rope lay the sling is
defective. A rope lay is the length along the rope where one strand makes a complete
revolution around the rope (See Appendix A). (Note: Some companies consider wire rope
slings to be defective when a single wire is broken. Be sure you are familiar with your
company’s policy regarding wire rope slings.)
• Examine the areas of wire rope that are close to attached fittings. If there is one or more
broken wires in any of these areas the sling is defective.
Any defective sling should be taken out of service. If you find any indication that any part of
a sling may be defective, or if you are not sure, take it out of service immediately and follow
the procedure for handling defective equipment.
INSPECTIONS
• Look for a permanently attached identification tag on each sling that states the size,
grade, rated capacity and the name of the manufacturer. If the identification tag is not
attached, the sling is defective.
• Only Alloy Grades 80 or 100 may be used for overhead lifting. If the sling does not meet
these criteria, take it out of service immediately.
Any defective sling should be destroyed immediately in accordance with your company
policy. If you find any indication that any part of a sling may be defective, or if you are not
sure, take it out of service immediately and follow the procedure for handling defective
equipment.
Rigging hardware can wear out over time. It can weaken and break from wear, misuse, and/or
abuse. It becomes dangerous when it can no longer safely support its rated capacity. Hardware
inspections are critical and should be performed before each use.
INSPECTIONS
• Look for identification markings on the hardware. If the identification information is
missing or illegible, the hardware is defective.
• Check the hardware carefully for cuts, gouges, corrosion, rust (other than surface rust),
and pitting. If any of these defects are present and appear significant, or if you are not
sure whether the hardware is safe to use, consider it defective.
• Check each piece carefully for melted areas, welding arc strikes, welding slag or other
hot work markings. If any of these defects are present and appear significant, or if you are
not sure whether the hardware is safe to use, consider it defective.
• Pay special attention to the area of the hardware that bears most of the weight of the load.
• Look for bent, twisted, stretched, cracked and broken areas on hardware, which render
the hardware defective.
Any defective hardware should be taken out of service. If you find any indication that any
part of the hardware may be defective, or if you are not sure whether it is safe to use, take it
out of service immediately and follow the procedure for handling defective equipment.
All types of slings should be protected from sharp edges, especially synthetic web slings, which
are most susceptible to cuts. To protect the slings, place padded material between the sling and
the edges. Make sure the material is strong enough to withstand the increased force of the sharp
edges against it when the load is lifted.
General
• The edges of the material being lifted do not have to be razor sharp to cut a sling that is
not properly protected.
• Wide synthetic web slings are particularly susceptible to tearing at their points of contact
with the corners of the load.
• Consider using commercial softeners for padding, or consider using commercial corner
protectors that force the sling to round out at the contact points.
Center of gravity is the point within the load at which the object balances evenly in all directions.
To ensure safe rigging it is important to identify the center of gravity so that the load will remain
stable throughout the lift. The load should be raised directly above the center of gravity
whenever possible.
It is easy to determine the center of gravity on objects that are uniform in shape and composition
such as a single piece of pipe. However, oddly configured objects require more trial and error to
determine the center of gravity. Once you have finished rigging the load, have the operator
carefully raise the load a few inches at a time, stopping and starting slowly so you can determine
whether the rigging needs to be adjusted. If the load tilts during the trial, signal the operator to
set it back down, and then re-rig the load. Follow this procedure as many times as necessary until
the load is stable.
Just before and during the lift there are several details that require special attention, including
testing the load, attaching tag lines, identifying potential obstructions, clearing the area, and
communicating with the operator.
• Ensure that the sling stays in the correct position as it tightens around the load.
• Watch for potential sling and hardware failures.
• Make sure the load is being raised straight up over its center of gravity so the load will
not swing.
• Be aware of potential pinch points and keep your hands and body clear.
• Also, be aware that the load could shift as it is lifted. Position your body so that you will
not be trapped or crushed if the load does shift.
If you detect any issues, or if you are not sure whether the load can be lifted safely, signal the
operator to set it back down and re-rig the load before testing it again.
Tag Lines
• Tag lines should be attached to the load to keep it from rotating and swinging out of
control during the lift.
• Use the number of tag lines and properly trained tag line operators that are necessary to
control the load safely.
• Make sure that all tag line operators and anyone else in the lift area is wearing a hardhat.
Potential Obstructions
• Consider where the load needs to be delivered in relation to where it is before the lift.
• Look for any obstructions that may be in the path of the moving load.
• Pay special attention to overhead power lines when watching for obstructions.
• If you detect a potential obstruction, check with the operator to ensure that he is aware of
the obstruction and has chosen a safe path for the load to travel.
Example: 1” shackle and 1 ½” wire rope Example: 2” shackle and 1 ½” wire rope
2”
1”
1 1/2”
1 1/2”
Shackle Orientations
• Check the weather conditions before the lift. If the weather is extreme, postpone the lift.
• Make sure you have good communication in place with the lift equipment operator.
• Rig the load so that it will be lifted straight up, which will help prevent the load from
swinging.
• Guide the operator to place the boom directly over the load, which will help prevent the
load from swinging.
• Make sure your hands are clear of pinch points when the sling starts to tighten around the
load.
• Watch carefully when the lift starts in case the load does swing.
• Be sure to stay out from under the load when it is being lifted and moved.
• Make sure the receiving area is firm, flat, and free from loose objects that could fly up
when the load is delivered. And, make sure the area is free from other obstructions.
• Guide the load onto the blocking so that it will not be dislodged.
• Watch the placement of your feet when you receive the load.
• Give the stop signal immediately if something does not appear to be safe.