This document provides information on lifting equipment and procedures according to factory safety regulations. It defines key terms like competent person and machinery. It outlines requirements for hoists and lifts under the Factories Act. Various types of lifting equipment and tackles are described, along with their functions. Guidelines are given for planning lifts, conducting the lift, landing loads, and dos and don'ts. Methods for determining safe working loads of various sling configurations based on sling angles are explained. Two case studies describe lifting accidents caused by improper lifting techniques.

1. Lifting EquipmentsLifting Equipments
and Procedureand Procedure
15 January 2011.
Compiled by
Safety Trainees
PECL

2. 2
2. Factories Act-Section 282. Factories Act-Section 28
(1):Hoists and Lifts(1):Hoists and Lifts
(a) In a factory hoists and lifts
should be of :
(i)-good mechanical construction
- sound material
- adequate strength
© SWL to be distinguishly marked and no load
greater than this be lifted or carried.

3. Sec 29. LIFTING MACHINES, CHAINS,
ROPES AND LIFTING TACKLES
3

4. 4
The Factories Act, 1948
Sec:2(ca): Competent Person
Means:
A person or an institution recognised as such by
CIF for carrying out tests, examination and
inspections required to be done in a factory under
provisions of this Act regarding:
(i)qualifications and experience of person and
facilities available at his disposal;
(ii) qualifications and experience of persons
employed in such institution and facilities a/v
therein, with regard to conduct of such tests,
examinations and inspections, and more than
one person or institution can be recognised
as a competent person in relation to a factory.

5. 5
The Factories Act,
1948
Sec:2(j): Machinery
Includes prime movers,
transmission machinery and
other appliances whereby power
is generated, transformed,
transmitted or applied.

6. Lifting Equipments:
 Hydra’s
 CRANES: limit switches
 Fork lifts
 Magnetic lift crane
 Mobile cranes: wheel ,crawler
 EOT
 Gantry
 Chain pully:spur gear,worm wheel
 Winch machine 6

7. Lifting tackle:
 Slings
 Ropes
 Shackles
 Swivel
 Rings
 Couplers
 Sockets, Eyebolts.
 Frames & spreaders
 Plate lifting clamps 7

8. Overview
 Terms & definitionsTerms & definitions
 Planning the liftPlanning the lift
 The liftThe lift
 Landing the loadLanding the load
 Do’s & Don’tsDo’s & Don’ts
 Case studyCase study
 Slinging methodsSlinging methods
 Safe slinging practiceSafe slinging practice
8

9. Terms & Definitions
 Competent person:
 A person who has acquired, through a
combination of qualifications, training or
experience, the knowledge and skill to
perform the task required.
 Grommet:
 Endless wire rope sling.
 MBL:
 Minimum breaking load of the lifting tackle.
 SWL:
 Safe working load.
9

10. Definitions
 Tag line:
 A rope of suitable strength, construction
and length attached with an appropriate
recognised bend or hitch to the load,
used to control the load during lifting or
positioning.
 Test certificate:
 A certificate issued by an authorized
person
10

11. 11
SIMPLE CHAIN PULLEY
BLOCK

12. Planning the liftPlanning the lift
Planning the lifting operation is essential
Planning the lifting operation is essential
to ensure that the lift is carried out
to ensure that the lift is carried out
safely and efficiently
safely and efficiently
12

13. Planning the liftPlanning the lift
Absence of planning leads to
Short cuts, using unsafe procedure, equipment
&
It may cause
An ACCIDENT OR DELAY
13

14. Planning the liftPlanning the lift
 The following points must be
considered during planning:
 Where the load is to be picked up from
 Where the load is to be placed
 What areas to be passed over
 Any obstructions in the way
 How the load is to be slung
 How the slings are to be removed and
access to them
14

15. Planning the liftPlanning the lift
 For complex lifts, following points may have
to be considered:
 Special lifting accessories such as spreader
beams to ensure that the load is safely lifted and
without damage to the product (large
machineries, generators, etc.)
 Special connectors to connect special built in
connecting points. The operations may involve:
 Turning loads over or standing them upright
 Using more than one crane to lift a load.
15

16. The liftThe lift
 Are the slings undamaged and properly attached
to the load?
 Is the crane hoist rope vertical?
 Is the load free i.e not attached to any thing
else?
 Are the legs of multi legged sling equally
loaded?
 Are all spare all spare legs of the sling are
hooked up to the master link on the lifting hook?
After slinging but before lifting, the followingAfter slinging but before lifting, the following
must be consideredmust be considered
16

17. The liftThe lift
 Are all personnel clear of the load?
 Is the landing site prepared to take the
load?
 If required, is hand/tag lines attached to
the load?
After slinging but before lifting, the followingAfter slinging but before lifting, the following
must be consideredmust be considered
17

18. Check Before LiftingCheck Before Lifting
 Now lift the load a short distance above the
ground and check that:
 The load is balanced and stable.
 The legs of the slings are at correct angles.
 Any packing pieces used, are in place and
sound.
 The load itself is not stressed, especially when
lifting packing cases, timber etc, which can fail
under the loads applied due to lifting.
18

19. Landing the loadLanding the load
 Before landing the load check that:
 The landing area will take the weight of the load.
 There is sufficient space for the load.
 There are strips of timber or similar on which to
land the load such that the slings can be easily
removed by hand.
 The load should be landed gently to
ensure that it is not damaged and
that the crane does not receive any
shock loading.
19

20. Do’s & Don’tsDo’s & Don’ts
 Ensure that only
authorized
slingers/signalers attach
or detach loads, or signal
the crane operator.
 Discuss operations with
the crane operator
(special operations).
 Ensure that the capacity
of the crane is sufficient.
 Seek expert advice when
using eye bolts, plate
clamp etc.
 Use tag line always
 Wrap tag line around
hand or body.
 Leave a suspended load
unattended.
 Pass loads over people.
 Ride or climb on
suspended loads.
 Stand or walk beneath
the loads.
 Use pipes to support
for landing the load
Always Never
20

21. 21
SWL OF SLINGS
SAFE
WORKING
LOAD OF
SLING
INCLUDED
ANGLE θ
SAFE
WORKING
LOAD
WITH ANGLEθ
G = 10 TON at
90
90 10 TON
160 3.45 TON
140 6.80 TON
120 7.07 TON
60 12.25 TON
P = G / Cos 45
0 14.14 TON
SWL at angle
=P X Cosθ /2

22. SLING ANGLES AND SAFE WORKING
LOADS
90˚ angle at hook
corresponds
to 45˚ sling angle
22

23. SLING ANGLES AND SAFE WORKING LOADS
.
23
When L = S
Sling angle is 60˚

24. SLING ANGLES AND SAFE WORKING LOADS
Calculating SWL
H is the vertical
distance from the
saddle
of the hook to the top of
the load.
L is the distance
measured along the
sling from the saddle of
the hook to the
top of the load.
The ratio H/L will be
same as the ratio h/l
24

25. SLING ANGLES AND SAFE WORKING LOADS
Determining
capacity of 2-Leg
Bridle
Hitch
SWL
= SWL (of single
vertical hitch) X H/L
X 2
25

26. SLING ANGLES AND SAFE WORKING LOADS
When sling legs
are not of equal
length
use smallest H/L
ratio.
26

27. SLING ANGLES AND SAFE WORKING LOADS
Determining
capacity of 3-Leg
Bridle
Hitch
SWL
= SWL (of single
vertical hitch) X H/L
X 3
When sling legs are
not of equal length
use smallest H/L
ratio.
27

28. SLING ANGLES AND SAFE WORKING LOADS
Determining capacity
of 4-Leg Bridle
Hitch
Load may be carried by
only 3 legs while
the fourth merely
balances it. Therefore
the recommended SWL
is:
SWL
= SWL (of single
vertical hitch) X H/L X 3
When sling legs are not
of equal length
use smallest H/L ratio.
28

29. SLING ANGLES AND SAFE WORKING LOADS
Determining capacity
of Single Basket
Hitch
For Vertical legs (fig A):
SWL = SWL (of single
vertical hitch) X 2
For inclined legs (fig B):
SWL
= SWL (of single vertical
hitch) X H/L X 2
29

30. SLING ANGLES AND SAFE WORKING LOADS
Determining capacity
of Double Basket
Hitch with inclined
angles
SWL
= SWL (of single
vertical hitch) X H/L X 4
30

31. SLING ANGLES AND SAFE WORKING LOADS
Determining
capacity of Double
Wrap
Basket Hitch
Depending on the
configuration, SWLs
are the same for the
Single Basket Hitch
or the Double Basket
Hitch.
31

32. SLING ANGLES AND SAFE WORKING LOADS
Sling angles less than
45˚ (formed by the
choker) are not
recommended. If
they
must be used the
formula is:
SWL
= SWL (of single
vertical hitch) X H/L
X
A/B X 2
32

33. SLING ANGLES AND SAFE WORKING LOADS
Determining
capacity of Double
Wrap
Choker Hitch
Depending on the
configuration, SWLs
are the same for the
Single Choker Hitch
or the Double Choker
Hitch.
33

34. Endless or Grommet Sling in
Vertical Hitch
34
Endless Sling choker Hitch
Configuration

35. SLING ANGLES AND SAFE WORKING LOADS
Endless Sling in
Double Basket
Hitch
Configuration
35

36. Endless or Grommet Slings Standard Eye-to Eye slings
36

37. SLING ANGLES AND SAFE WORKING LOADS
37

38. Effect of sling angle on
Webbing
38

39. Twisted Eye Slings
39

40. What can happen, if, adequate
safety is not observed?
40

41. A case study 1
 The incident:
 In June 2003, a tragic incident
occurred at one of the oil and gas
development site in Algeria, resulting
in one fatality and two injuries.
 The incident occurred during the assembly
of an onshore drilling rig. A large section
of the rig was being lifted when a lifting
chain failed.
41

42. A case study 1
Actual measurement to
hook position was 9.43 m.
7.5 m to centre of crane
slew ring correct jib
head/hook position
Probably out of
alignment in this
direction (this would
transfer entire load to
one sling)
Chain being pulled into
angle would increase
tendency to jam and
prevent chain slipping
round to equalize
loading
Sketch of out-of-alignment load path
during lift, resulting in lifting chain
failure 42

43. A case study 1
 The causes, as established by an investing
team:
 Use of an underrated chain sling.
 Incorrect slinging and lifting techniques.
 The crane hook was positioned off-centre,
resulting in the load path being out of
alignment.
 Combined with a hinged load, this prevented the
sling from equalizing on all chain legs when
raised.
 Consequently, the entire load of 23.1 tonnes
was placed on one chain leg that had a breaking
load of 18.9 tonnes resulting in failure of chain
43

44. Case Study 2
 Job : erection of gantry crane beams
 Description of Accident:
 Two beams of 11.5m X 1.5m X 0.75m
weighing about 6 tones were lying on
concrete sleepers.
 Out of two beams one beam was lying on
sleeper in horizontal position.
 The other beam was in vertical position and
was to be positioned to make alignment with
the first beam.
44

45. 45

46. Case Study 2
 Job : erection of gantry crane beams
 Description of Accident:
 Slings were placed around the vertical beam.
 Mr. XYZ went up the beam to adjust the sling.
 He adjusted the sling and stood in between the
two beams.
 In the meantime someone gave signal to lift the
beam.
 Crane operator lifted the beam by about 4 mm
up its position.
46

47. Case Study 2
 Job : erection of gantry crane beams
 Description of Accident:
 During that operation beam swayed
towards the first beam and Mr. XYZ was
caught between the two beams.
 On hearing the scream, crane driver
placed the beam back on its original
position.
47

48. Case Study 2
 Job : erection of gantry crane beams
 Description of Accident:
 Mr. XYZ got up and tried to get out of
two beams but he stumbled and fell
down on sleepers, got injury near left
eyebrow.
 He was taken to hospital, but was
declared as dead.
48

49. Case Study 2
49

50. Case Study 2 - Investigation
1. No hand rope (tag line) was used to avoid
swinging of the job.
2 Both the lifting rope used are having N no. of
kinks on it., naturally these kinks will have
tendency to swing the job.
3. No lifting hole or lugs were made to the beam
to rotate it.
4. Crane operator does not know who gave
him signal for lifting the job.
50

51. Learning from the incidents
Apart from lifting machine, it
is also necessary to take care
of lifting tackles and lifting
procedure
51

52. Safe Slinging Practice
52

53. Safe Slinging Practice
C.G.
Crane hook must
be on the CG
53

54. Safe Slinging Practice
This load is not stable. The hook is over
the CG, but the CG is above the lifting
hook.
This load is top heavy, and could
overturn while being lifted
54

55. Safe Slinging Practice
This load is stable
The hook is right over
the CG.
55

56. Safe Slinging Practice
The hook is not over
the centre of gravity
The load will shift until the
CG is under the hook.
This will make landing the load
very difficult, and could cause
major problems in crainage
Unstable
56

57. Safe Slinging Practice
1000
kg
1000
kg
1000
kg
1000
kg
45
90 90
45 30 30 1515
707
Kg
500
Kg
500
Kg
707
Kg
1000
Kg
1000
Kg
1932
Kg
1932
Kg
57

58. How to identify the correct
angle?
58
45
H
L
At 45 degrees, H = L
As the angle becomes
less than 45 degrees, H
will be less than L
Therefore ensure that
H is always = or > L

59. Safe Slinging Practice
Can carry
88% of
rated load
Can carry
100% of
rated load
Can carry
80% of
rated load
Can carry
70% of
rated load
Can carry
40% of
rated load
Balanced
load
¼” off
centre
1/2” off
centre
3/4” off
centre
Point
loading
Safety latches
omitted 59

60. Safe Slinging Practice
Softeners, padding or use of blocking..
60

61. Safe Slinging Practice
Tag line should be attached to the load swinging and to help it
landing in the right place.
61

62. Unsafe Slinging
Lift and lower the load
smoothly, do not jerk
62

63. Unsafe Slinging
63

64. Unsafe Slinging
64

65. Unsafe Slinging
65
Is it right method
to extend a chain
sling?

66. Unsafe Slinging
66

67. Sling storage
67

68. Hand SignalsHand Signals
 When should the crane operator
follow hand signals?
 A crane operator should always move
loads according to the established code
of signals, and use a signaler.
 Hand signals are preferred and
commonly used.
68

69. Hand SignalsHand Signals
 Who can give the hand signals?
 a person qualified to give crane signals
to the operator,
 there should be only one designated
signaler at a time,
 a crane operator should move loads only
on signals from one signaler,
69

70. Responsibility of the signaler
 The signaler must:
 be in clear view of the crane operator,
 have a clear view of the load and the
equipment,
 keep persons outside the crane's
operating area,
 never direct a load over a person.
70

71. Standard Hand Signals For
Controlling Overhead Cranes
With forearm
vertical, forefinger
pointing up, move
hand in small
horizontal circle
HOIST
71

72. Standard Hand Signals For
Controlling Overhead Cranes
With arm extended
downward,
forefinger pointing
down, move hand in
small horizontal
circle.
LOWER
72

73. Standard Hand Signals For
Controlling Overhead Cranes
Arm extended
forward, hand open
and slightly raised,
make pushing
motion in direction
of travel.
BRIDGE TRAVEL
73

74. Standard Hand Signals For
Controlling Overhead Cranes
TROLLEY TRAVEL.
Palm up, fingers
closed, thumb
pointing in direction
of motion, jerk hand
horizontally.
TROLLEY TRAVEL
74

75. Standard Hand Signals For
Controlling Overhead Cranes
Arm extended,
palm down, hold
position rigidly.
STOP
75

76. Standard Hand Signals For
Controlling Overhead Cranes
Use one hand to give
any motion signal
and place other
hand motionless in
front of hand giving
the motion signal.
(Hoist Slowly shown
as an example.)
MOVE SLOWLY
76

77. Standard Hand Signals For
Controlling Overhead Cranes
Crane operator
spreads both
hands apart –
palms up.
MAGNET DISCONNECTED
77

78. Finally, we must remember….
78

79. Objective Of Good SlingingObjective Of Good Slinging
 The sling and its method of use should
be suitable for the load.
 The method of attachment of the sling
to the load and the sling to the lifting
appliance should be secure.
 No part of the sling should be
overloaded either by the weight of the
load or by the method of slinging.
79

80. Objective Of Good SlingingObjective Of Good Slinging
 The slinging method should ensure
that the load is secure and that the
load will not fall from the sling.
 The load should be balanced and stable
and should not violently change its
attitude when lifted.
 The load must not be damaged by, or
cause damage to, the sling.
80

81. If we remember & achieve
this Objective…..
The probability of
accident will be
minimum

82. Sling storage
82

83. 83