MATERIAL HANDLING

Safe Rigging Practices

Know How to Do It Right!

Then Do It Right!
 THE NEED FOR
MATERIALS HANDLING
• Required to handle materials in
office, home, site, etc.
• 25% of total accidents are due to
materials handling
• Materials handling from Prehistoric
times
 PRE-HISTORIC TIME
MATERIALS HANDLING
The gigantic pyramid at Giza near Cairo
(Egypt) built about 2700 B.C. which is 764 ft
square at the base and 480 ft. high. About
2(1/3) million stones from 2 to 30 tons in
weight each were transported from the quarry
to the Nile River at the flood season,
ferried across the river on rafts, dragged
from river to the site of the pyramid and
piled up on each other to a height of a 40
storied building. It is believed that a ramp
was built up on one side of the pyramid and
the stones were dragged up the slope by
slaves working in teams.
MATERIAL HANDLING

WE SHALL DISCUSS ABOUT

• Material Handling Problems.

• Ropes.
• Rigging and safe rigging practice.
•“D” Shakle.
•Case Study.
MATERIAL HANDLING
PROBLEMS
LEAD TO INJURIES DURING THE COURSE OF
MATERIALS HANDLING e.g.

• CUT INJURIES
• BRUISES
• SPRAIN & STRAIN
• CRUSH INJURIES
• FRACTURE
MATERIAL HANDLING PROBLEMS….

THESE INJURIES ARE DUE TO

• UNSAFE WORKING PRACTICES
• IMPROPER LIFTING
• CARRYING TOO HEAVY LOADS MANUALLY
• INCORRECT GRIPPING
• NOT USING PPE
• FAILING TO HAVE PROPER FOOT AND HAND
CLEARANCES, ETC.
ROPES
ROPES….
COMMONLY USE OF

• FIBRE ROPES
• WIRE ROPES
FIBRE ROPES USAGE

• For light loads

• For construction
• Painting Jobs
• Marine Works
FIBRE ROPES TYPES

• Coconut Coir Rope

• Cotton Rope
• Jute Rope
• Manila Rope
 FIBRE ROPES
10 USEFULL TIPS ON HANDLING CARE & USE OF FIBRE ROPE

1. It should be hung up in loose coils on large diameter

wooden pegs.
2. It should be kept away from heat sources.
3. It should be kept away from acid fumes.
4. For opening a new coil of rope, the end of the rope
should be at the bottom of the core or eye and the
end should be pulled out through the core. If this is
not followed kinks will be formed which will damage
the rope.
 10 USEFULL TIPS ….

5. When used as slings should not be passed over sharp

edges. Proper padding should be used.
6. Strength of Fibre Ropes
1. At 60 ° -- 86 % of their strength when vertical
2. At 45 ° -- 71% of their strength when vertical
3. At 30 ° -- 50% of their strength when vertical
7. Rope should not be dragged on ground to avoid
abrasive action.
8. Fibre rope should be inspected thoroughly before and
after use.
 10 USEFULL TIPS ….

9. When a rope is condemned, it should be destroyed at

once to cut up into short hand lines so that it cannot
again be used for hoisting.
10. If the rope is used for lifting loads with pulley blocks,
it is advisable to reverse the ends periodically so that
the rope is worn out more or less uniformly through-
out.
WIRE ROPES
A Wire Rope is usually made up of a
number of wires laid left or right
handed into a strand and number of
wires laid left or right handed into a
strand and number of strands, usually
6 or 8, laid right or left handed round a
hemp rope center to form the wire
rope, or steel cable as it is generally
called.
 WIRE ROPES
CONSTRUCTION OF WIRE ROPES
 WIRE ROPES
There are 4 different ways of laying the wire
rope.
1. Right-lay, regular-lay
2. Left-lay, regular-lay
3. Right-lay, lang-lay
4. Left-lay, lang-lay
 WIRE ROPES
CONSTRUCTION OF WIRE ROPES:

There are a different possible constructions of

wire rope.
(Number of Strands) X (Number of Wires in a Strand)
Example:
6X7  6 Strands and 7 Wires in each strand
6X19  6 Strands and 19 Wires in each strand
6X37  6 Strands and 37 Wires in each strand
 WIRE ROPES
COMMON USE OF VARIOUS CONSTRUCTION OF WIRE
ROPES

6X7 (Regular Lay)  Guys, Suspension Ropes, etc.

6X19 (Regular lay with hemp core)  Slings,
elevators, etc.
6X19 (Regular lay with steel core)  Blast furnace
bell hoist
6X37 (Regular lay with hemp core)  Overhead
Cranes, Mill Hoist, etc.
6X37 (Regular lay with steel core)  Hot Metal
Cranes, Blast Furnace bell, etc.
 WIRE ROPES
INSPECTION OF WIRE ROPES

•BROKEN WIRES

•WORN OUT WIRES

•REDUCTION IN ROPE DIA.

•ROPE STRETCH

•BIRD CAGE

•KINKS

•CORE PROTRUSION
 WIRE ROPES
BROKEN WIRES

•6 OR MORE BROKEN
WIRES IN ONE LAY
•3 OR MORE BROKEN
WIRES IN ONE STRAND IN
ONE LAY
•MORE THAN 5% IN ANY
LENGTH OF 10 DIAMETERS
 WIRE ROPES
REDUCTION IN ROPE DIA.
REPLACE THE WIRE ROPE IF THE DIA REDUCES BY

•1mm FOR ROPE DIA UPTO 19mm

•1.5mm FOR ROPE DIA UPTO 22-28mm

•2mm FOR ROPE DIA UPTO 32-38mm

ROPE STRETCH
150 mm PER 30m LENGTH OF SIX STRANDED ROPE
WIRE ROPES
BIRD CAGES
WIRE ROPES
CORE PROTRUSION

L&T-HSE
 INSPECTION PROCEDURE

Coding

Once in a month

Coloring

Announce

Record
‘U’ CLAMPS
DISTANCE BETWEEN THE ROPE CLIPS = 6 X Dia.

CLIPS AND SPACING FOR SAFE APPLICATION

Rope Diam. Minimum No. Clips Spacing of Drop
In. for Each Rope End Forged Clips
in.
1/2 3 3
5/8 3 3.3/4
3/4 4 4.1/2
7/8 4 5.1/4
1 5 6
1.1/8 6 6.3/4
1.1/4 6 7.1/2
1.1/2 7 9
RIGGING
 SLINGS
TENSION ON SLINGS

T=WxL
HxN

T = TENSION

W = WEIGHT OF THE LOAD

L = LENGTH OF SLING

N = NO. OF SLING LEGS

 SLINGS
TENSION ON SLINGS

If L is greater than S
then sling angle is OK
SLINGS - HITCHES
BASKET HITCH
SLINGS - HITCHES
CHOKER HITCH
 RIGGING PRECAUTIONS

Weight of ALL loads

Allowances for unknown factor

Capacity of equipment &

marked
 RIGGING PRECAUTIONS

Rapid swinging increases the

stress

Avoid bending splice/ eye section

around the corners.

Avoid dragging of sling beneath

loads
 RIGGING PRECAUTIONS

Sharp Bends , Pinching &

crushing –avoid for slings –
provide packing- curve 7 lays

Never wrap a wire rope

around a hook.
 RIGGING PRECAUTIONS
LIFTING
Suspended loads –securely slung & properly
balanced
Tag Line
Safely landed & blocked
Lifting beams –SWL marked.
Hoist rope – don’t wrap it around the load.
Multiple part lines –don’t twist
Slack rope condition –ensure it is seated properly on
the drum
Stand clear of the load
 SHACKLES
DEFECTS: INSPECTION OF D-SHACKLES
•SAFE WORKING LOAD MISSING
OR UNREADABLE

•IDENTIFICATION MISSING
•OR UNREADABLE

•INCORRECT PIN

•DAMAGED THREAD ON PIN OR IN

TAPPED EYE

•DISTORTED BODY

•WORN OUT BODY OR PIN

•NICKS, GOUGES, CRACKS,

•CORROSION
 Shackle

JAW INSIDE BODY PIN EYE

SAFE WORKING LOAD TONNES
INSIDE LENGTH MATERIAL DIAMETER OUTSIDE
WIDTH DIAMETER DIAMETER
GRADE 30 GRADE 40 GRADE 63
W s = 2.2W d Dmin emin
22 49 14 16 32 1 1.25 1.6

32 70 19 22 44 2 2.5 3.2

50 110 30 35 70 5 6.3 8

70 154 43 50 100 10 12.5 16

90 198 54 62 124 16 20 25

100 220 60
L&T-HSE 138
69 20 25 32
L&T-HSE
 Observation
• Alignment of the boom top and the centre of the
load was not proper during lifting operation which
caused swinging of the load

Remedy
• Before lifting of load the top of the boom and the
centre of the load to be aligned properly to avoid
swinging.
• Experienced Signal man should facilitate the same

L&T-HSE
L&T-HSE
L&T-HSE
 Observation
• Defective storing. Plates were kept in vertically
inclined position by means of make shift
arrangement

• Work method / Job Safety analysis not prepared

Remedy
• Suitable stands to be used for keeping plates
vertically
• Work method statement / Job Safety analysis to be
prepared and implemented
L&T-HSE
L&T-HSE
 Observation
• Used worn threaded D-shackle
• Checking of casing pipe and operation of the rig
were simultaneous
• The rig is operated inside the excavation. No space
to run off
• Routine checkup not made before starting fresh pile
• Over confidence / carelessness of both rigger as well
as rig operator
• Though the pin of D-shackle released from its
position is happened repeatedly none has given
solution to avoid its recurrence

L&T-HSE
 Remedy

• Routine visual check-up should be made before

starting each pile by job engineer
• While checking welded joints of the casing pipe, the
rig hammering should be paused
• Worn threaded D-shackle shall be discarded by
means of lifting tools n tackles check, colour code
etc.
• Frequent pep talk and toolbox meeting to be
conducted

L&T-HSE
L&T-HSE
 Observation
• Use of improper sling
• Tag line / guiding ropes were not used for guiding
the load from a safe distance, from crane
• The plate was tied with a single sling. In order to
compensate the sling length, plate width and ground
clearance the boom of Hydra was lifted to almost
full, leading to just a gap of approx. 1 foot between
the rear end of plate and front wheel of Hydra
• The victim was walking in front of crane holding the
rear end in very close proximity to the wheel, at the
left side of the road

L&T-HSE
 Remedy
• Proper sling to be used
• The use of guide ropes for controlling the load while
travelling with crane; in order to keep workmen
away from the crane range and load, should be
ensured
• Worker should not be very close to the crane while
walking along with the load
L&T-HSE