LEARNING GUIDE LINE H

LIFT LOADS
TRfiC
COMMON CORE

LEARNING GUIDE LINE H l.lFT LOADS TRAC COMMON CORE

Province of British Columbia Ministry of Post-Secondary Education

1986
Reprinted by Ministry of Education, Skills and Training 1998

Canadian Cataloguing in Publication Data Main entry under title: TRAC common core Contents: line H. Lift loads ISBN 0-7726-0297-2 (set). -- ISBN 0-7726-0339-1 (line H) 1. Occupational training - British Columbia. I. British Columbia. Ministry of Post-secondary Education. II. Title: Lift loads. HD5715.5.C32B74 1986 331.25'92'09711 C85-092131-7

For further Information regarding Trades Programs contact:

Co-ordinator, Trade Programs Ministry of Education, Skills and Training Parliament Buildings Victoria, B.C. V8V 1X4 Telephone: (604)356-8088

Copies of this publication may be ordered from:

Provincial Curriculum Publications Marketing Department Open Learning Agency 4355 Mathissi Place Burnaby, B.C. V5G 488 Telephone: (604) 431-3210 Fax: (604) 431-3381 Toll-free in B.C.: 1-800-663-1653

Copyright

1986, Province of British Columbia, Ministry of Post-Secondary

Education

Contents
H-1 ...... 1

H-2 .......

31

SELECT LIFTING AND HOISTING EQUIPMENT

H-3

85

H-4

113

Competency H-1 Tie Knots, Bends and Hitches

Learni ng Task 1: fibre ropes ... Self Test 1

3 8

of fibre

ropes ........................

11
14

h;

tc h es ...........................

17

Self Test 3 .......................... 25

h ; tc hes ........................... Check 1i s t 1 .............................

29 30

Requirements
Learning Tasks Very few people can make it through life without ever using ropes or tying knots. A task as simple as tying a load on the back of a truck becomes almost impossible unless you have some knowledge of ropes and knots. To effectively use ropes in a work setting requires that you become familiar with several types of ropes, knots, bends and hitches. When you have completed the Learning Tasks in this competency, you should be able to: . identify several types of ropes, . select the correct rope size and rope type for given tasks, describe how to care for fibre ropes, identify eight knots, bends and hitches, select the correct method of securing fibre ropes for specific tasks, and tie eight knots, bends and hitches.

Competencies

You will be tested on your knowledge of types of fibre ropes and their uses, rope strengths, knot identification, uses of knots, bends and hitches, and care of fibre ropes. You must achieve at least 80% on this Written Competency. PRACTICAL: You will be required to tie eight knots, bends and hitches. You must achieve at least 80% on this Practical Competency.

Learning Task 1: Identify natural and synthetic fibre ropes

Shock load: Static load: Breaking strength:

a load or pull which is applied suddenly rather than gradually. a load which is stationary or a pull which is steady. the smallest load that will cause a rope to break.

Fibre ropes Fibre ropes may be made from either natural or synthetic fibres. Natural rope fibres such as manila or sisal are made from plants. Synthetic fibres are nylon, polypropylene and polyester. Each of the above fibres has properties which cause them to react differently in certain situations.

Manila rope is light yellow in colour and has a smooth waxy surface. ropes are available in six grades:

Manila

highest quality manila rope. Very pale yellow in colour. Costly and used only on special jobs. high grade rope, pale yellow in colour. Falls between yacht-rope and No.1 grade rope in strength. light yellow in colour. Usually has one or more coloured strands to identify it as No.1 grade rope. No.1 grade manila rope is the grade suitable for construction rigging and hoisting. sightly darker than No. 1 rope and does not have coloured identity strands. Loses strength more rapidly than No.1 grade.

considerably darker in colour than No.2 and No.1 rope. Loses strength very rapidly when in service. Hardware store rope: darkest and poorest grade of the manila ropes. Hardware store rope is constructed with a high percentage of short fibres giving it little strength, short life and a much rougher texture as many fibre ends protrude from the rope's surface.

Sisal ropes are white, coarse-textured and rough to the touch. Sisal ropes are weaker than manila and should be used only where cost rather than strength is the major factor.

Nylon is approximately 2 1/2 times stronger than manila. Nylon rope is usually pure white, soft and pliable, elastic, and smooth to the touch . Nylon ropes lose about 10% of their strength when wet, but regain their original strength when dried. Nylon does not rot, is unaffected by mildew and can be used at temperatures up to 150C (300F) without damaging the rope. The highly elastic nature of nylon rope makes it capable of withstanding repeated shock loads. However, this same elasticity can be a hindrance if you are trying to lift loads in areas with restricted headroom.

Polyester rope is similar to nylon in appearance but is not as elastic. While nylon rope will stretch up to 40% of its no-load length, polyester rope will stretch only 5% before breaking. Polyester ropes are 87% as strong as nylon but, due to this lack of elasticity, are capable of sustaining only approximately 60% of the shock load nylon ropes can sustain.

Polyester does not lose any strength when wet and, unlike nylon, is unaffected by acids or alkalines. However, for your own protection, you should wash polyester ropes and slings with cold water whenever they have been exposed to any chemicals.

Polypropylene ropes are available in a wide range of colours, but yellow is most common. Poly ropes are smooth and somewhat slippery. They are light in weight and will float on water. Polypropylene will gradually soften as temperatures increase and will lose 40% of its strength at the temperature of boiling water (100C or 212F). Hotter temperatures will eventually cause polypropylene to melt. Polypropylene ropes are 60% as strong as nylon and are capable of absorbing shock loads only 40% that of nylon. However, of all the rope types mentioned, polypropylene has the best insulating properties against electrical shock. It should be noted that only dry ropes should be used near sources of high voltage.

Relative strengths When selecting a rope for a given task, the rope strength is usually one of the first factors to consider. The chart in Figure 1 shows the relative strengths of dry ropes of equal diameter. Since nylon is the strongest, it is listed as 100%.

Type of rope Nylon Polyester Polypropyl ene Manila

Relative dry strength 100% 87% 60% 37%

Sisal is not listed in Table 1 because the Workers' Compensation Board does not consider it acceptable.

Safe working loads

l;{ [I]

In the trades at the present time, safe working loads are calculated using imperial measurement.

Safe working loads for ropes are derived from the breaking strength of that rope. The Workers' Compensation Board requires a safety factor of 5 for ropes used to lift materials and a safety factor of 10 for ropes used to lift or support personnel. The safe working load of a rope is therefore its breaking strength divided by the required safety factor. If a manufacturer rates a rope's breaking strength at 1500 lbs. you can calculate its safe working load (SWL) for lifting materials as follows: 1500 lbs. SWL = ---5

SWL = 300 lbs.

1500 lbs.
10

or half the safe working load for that of materials. If you are unable to locate the manufacturer's rating for rope, the following general guidelines will enable you to calculate safe working loads for materials (safety factor of 5).
Nylon rope

1. 2.

Change the rope diameter to its equivalent in eighths of an inch. Square the numerator of the resulting fraction and multiply this square
by 60.

For example: 3/4

11

nylon rope = 6/8

11

diameter

Polypropylene rope

1. 2.

Change rope diameter to its equivalent in eighths of an inch. Square the numerator of the resulting fraction and multiply this square
by 40.

For examp,le: 3/4" polypropylene rope = 6/8" diameter SWL = 6 x 6 x 40 = 1440 lbs.

1. 2.

Change rope diameter to its equivalent in eighths of an inch. Square the numerator of the resulting fraction and multiply this square by 20.

3/4" manil a rope SWL = 6 x 6 x 20

6/8" diameter 720 lbs.

I~I

You must bear in mind that the preceding formulas include a safety factor of 5 (as required for materials). If you wish to calculate the safe working load for personnel (safety factor 10) simply divide the safe working loads which you calculated above by 2.

Now complete Self Test 1 and check your answers.

Choose the best answer for the following questions. 1. The lowest grade of manila rope which should be used for lifting or rigging in construction is a. b. c. d. 2. yacht rope bolt rope Number 1 grade Number 2 grade

Sisal rope is easily distinguished from manila rope because sisal rope
is

a. b. c. d.

darker in colour coarser in texture smoother to the touch softer and more pliable

a. b. c. d. 4.

Number 1 grade yacht rope hardware store rope bolt rope

The strongest of the ropes listed below is a. b. c. d. polypropylene sisa1 polyester manila

5.

The rope with the greatest degree of elasticity is a. b. c. d. nylon polyes ter polypropylene manil a

6.

The best type of rope to use if an electrical hazard exists is dry a. b. c. d. manil a polypropylene polyester nylon

7.

When loaded to the breaking point, nylon rope will have stretched up to a. b. c. d.
10% 20% 30% 40%

its its its its

original original original original

length 1ength length length

8.

Which of the ropes listed below will float on water? a. b. c. d. nylon polypropylene polyester manila

9.

Which of the ropes listed below is least able to withstand high temperatures? a. b. c. d. nylon polypropylene polyester manila

a. b. c. d.

sisal number 3 grade manila polypropylene bOlt-rope manila

11. Ropes used to lift or support personnel must have a safety factor of

a.
b.

2
5

c.
d.

10
50

12. The safe working load for 1/2" nylon rope used to lift materials is a. b. c.
d.

240lbs. 320 1bs. 640 1bs.

960 1bs.

13.

If the manufacturer's label lists a rope's breaking strength at 3000 lbs. it could be used to lift materials weighing up to a. b. c. d. 600lbs. 1000 1bs. 1500 1bs. 2000 1bs.

14.

If a rope has a safe working load (for materials) of 1200 lbs., you could use it to support personnel to a maximum of a. b. c. d.
200 1 bs. 300 1bs. 400 1bs. 600 1bs.

Learning Task 2: Describe the care and maintenance of fibre ropes

The life of any type of fibre rope can be greatly extended if you follow the basic care and maintenance procedures listed below:

Coiling and uncoiling Rope should be coiled in a clockwise direction and unwound in a counterclockwise direction. Any kinks or small loops should be carefully removed before a rope is pulled taut. To remove new rope from its shipping coil, place the coil on its side, reach down inside the coil and pull the rope up from inside the coil. Leave the outer wrapping intact.

Whipping Whipping is a wrapping applied at the end of a rope to prevent the rope strands from unravelling. Whenever a rope is cut to a new length, the ends of the rope should have whipping applied before the rope is put into service. Whipping is more than just a tidy decoration. It serves to prevent the strands of the rope from slipping in relation to each other. Such slipping would cause one strand to carry more (or less) than its fair share of the load. To apply whipping to a rope you should use a strong, non-slipping twine. the twine tends to slip, pulling it over soft tar, beeswax or pine pitch will correct the problem. Begin by holding one end of the twine (A in Figure I) at the end of the rope. Then form along loop along the rope. Hold the end of the twine (A) and the 1eft end of the loop with you r 1eft hand and begin wrapping the other end of the twine (B) around the rope over the long loop.
A~

If

Continue to apply tight wraps as close to each other as possible until you have covered a distance of approximately 1 1/2 times the rope diameter (Figure 2). Take the twi ne-end (B) and pass it through the loop (Figure 2). Pull on the twine end (A) until you feel the two ends of the twine are approximately mi dway under the whipping (Figure 3). Trim the ends of the twine as close as possible to the whipping, then trim the end of the rope so that a portion approximately half the rope diameter projects beyond the whipping (Figure 4).
~

!i:'

The whipping on nylon, polyester or polypropylene ropes may be eliminated by melting the fibres together with a hot iron or flame. Take care not to burn yourself with the hot material. Be prepared to roll the end of the melted rope between two flat surfaces (scraps of wood) while the rope cools; otherwise, you may have the end larger than the diameter of the rope. Ropes with ends larger than their diameter are sometimes difficult to untie. Tape should not be used as whipping. and has a tendency to become undone. It cannot be applied tightly enough

Storage Improper storage of fibre ropes can lead to such defects as rot, brittleness, crushed fibres, embedded dirt, kinks and many other defects. Properly stored fibre ropes will give years of trouble-free service. 1. Be sure to coil ropes clockwise. Hang coiled ropes on large diameter pegs in a cool, dry place, where there is good air circulation to prevent mildew. Clean and dry ropes before storing them. Wash ropes with cool water then hang them loosely coiled in a well ventilated area to dry. Stored ropes should be protected from moisture, heat and direct sunlight.

2. 3.

Misusing or abusing rope will greatly reduce the rope1s strength and ease of handling, and will shorten its life span. To ensure that a rope will perform as expected you should use these common sense rules whenever you use a rope.
1.

Keep ropes clean. Soil embedded in the rope1s fibres acts as an abrasive, wearing down the fibres. Wash soiled ropes with cool water and dry them naturally (no heat) before putting them away. Do not overload a rope. The maximum load placed on any rope should never exceed 1/5 the breaking strength of that rope. Do not use a frozen rope. Bending it may break the frozen strands. Handle the rope very carefully until it has thawed. Dry the rope to prevent it from freezing in cold weather. Avoid exposing a rope to direct sunlight for long periods of time. The sun's rays cause rope fibres to break down. Avoid sharp bends with a rope. Always pack or pad all but rounded corners of a load before lifting it or tying it down with rope. If a rope is being attached to a smalldiameter object such as a hook or a ring, use a metal thimble as illustrated in Figure 5 to protect the eye (or loop) of the rope. Remember that a sharp bend (even that of a knot) will reduce the strength of a rope
by 50%.

2. 3.

4.

5.

6.

Figure 5 Metal thimble in use

Ropes require very little maintenance other than a thorough cleaning whenever they become soiled. Whipping should be replaced when it shows signs of fraying or loosening. The best form of maintenance is, in fact, careful use.
", Now complete Self Test 2 and check your answers. 13

Choose the best answer for the following questions. 1. To remove new rope from its shipping coil you should a. b. c. d. 2. pull it from the inside of the coil roll the coil across the floor mount the coil on an axle cut portions from the side of the coil

If the twine used for whipping is slippery, you should a. b. c. d. apply parafin wax to the twine add 1inseed oi1 to the rope soak the twine in honey pull the twine through beeswax

3.

The length of the rope which projects past the whipping should be approximately a. b. c. d. two twine thicknesses half the rope diameter one rope diameter two rope diameters

4.

Whipping should be continued along the length of a rope for a distance equal to a. b. c. d. half the rope's diameter one rope diameter one and one half rope diameters two rope diameters

5.

Instead of wrapping the ends of synthetic rope with twine whipping you may use a. b. c. d. tape glue nothing; synthetic ropes don't unravel heat to melt the fibres

a. b. c. d.

tightly in a clockwise direction in a counterclockwise direction into a box

a. b. c. d. 8.

well ventilated moi st above 25C (77F) exposed to sunlight

If you hang a coil of rope on a peg, the peg should be a. b. c. d. perfectly level sloping towards the wall made of wood large in diameter

a. b. c. d.

lubricant abrasive conductor bonding agent

a. b. c. d.

3/4 of its breaking strength half its breaking strength one fifth its breaking strength one tenth its breaking strength

11. Rope can be prevented from freezing in cold weather by storing it a. b. c. d. tightly coiled in a box wrapped in plastic dry

12.

Sharp bends and knots can reduce the strength a. b. c. d.

25% 40% 50% 85%

of a rope by up to

Learning Task 3: Identify eight knots, bends and hitches

To make effective use of any rope you must first be able to select the correct knot, bend or hitch for a given situation, and then be able to tie it. Any knot, bend or hitch must support the load imposed on it, be quick and easy to tie, and be easy to untie once its load has been removed.

Bend: Hitch:

the intertwining of the ends of either one or two ropes to make one continuous or endless rope fastening used to attach a rope to a post, pole, ring, hook or other object

Parts of a rope To better understand the following instructions on knot tying, you will need to identify the parts of a rope. Figure 1 shows a loop which is the starting point of most knots. The portion of the rope which forms the loop is termed the "bight". The long portion of the rope will be termed the "standing part". The end of the rope will be called just that, litheend".

STANDING PART

The loop in Figure 1 is formed by passing the end of the rope "over" or "in front of" the standing part of the rope. As shown in Figure 2, a loop can also be formed by passing the end of the rope "under" or "behind" the standing part of the rope. Figure 2

STANDING PART

The following eight knots, bends and hitches are demonstrated in the video, Knot Tying, which you will view at the end of this learning task. You may want to view the video at this point as well.

The bowline knot (Figure 3) forms a non-slip loop at the end of a rope. To tie a bowline, begin by forming a small loop by passing the end of the rope over the standing part. Pass the end under the bight and pull it up through the loop. Pass the end behind the standing part, then back down through the loop. Tighten the knot by holding both the end of the rope and the loop in one hand and the standing part in the other hand and pull until the knot is tight.

To untie the bowline, loosen the knot by pushing the loop which is around the standing part of the rope away from the knot. Once the knot is loosened it is easily untied. The bowline can be used anytime a slip-proof loop is needed.

The half hitch is used for temporarily attaching a rope to an object when the pull will be at right angles to that object. The half hitch is used with other knots to prevent them from coming untied. As illustrated in Figure 4 the rope is passed around the object, then the end is passed around the standing part of the rope. The end is then pinched between the rope and the object being tied.

For safety, the end of the rope must be pinched to the object being secured at a point almost opposite the standing part of the rope. As well, the pullan the standi ng part of the rope must not be relaxed as this may allow the hitch to come untied. As illustrated in Figure 5, the half hitch is most often tied to the standing part twice, making a secure fastening. It is very important that you make both loops around the standing part in the same direction. If you make one loop clockwise and the other counterclockwise you will find it very difficult to untie the hitch. To make the double half hitch illustrated in Figure 5 you must first pass the rope around the object being attached. Then pass the end of the rope around the standing part of the rope and pull the end between the object and the rope. Continue with a second loop around the standing part of the rope~ making sure both 100ps are made in the same direction. Finish by passing the end of the rope between the standing part of the rope and the two loop s.

As the standing part is pulled tight, the loop around the object will slip until the two half hitches have jammed tight to the object. They will not come untied if the pull on the standing part is relaxed.

The clove hitch is used to secure a rope to a fixed object, such as a post. To tie a clove hitch (Figure 6), take two wraps around the object. The first wrap is made to one side of the standing part and the second wrap must be to the opposite side of the standing part. The end of the rope is then passed between the object and the second wrap. The two wraps are then pulled close to each other and the standing part and the end pulled in opposite directions.

The clove hitch can be made even more secure by tying the end to the standing part with a single half hitch.

The timber hitch is used to secure a rope to a plank, timber, post or pipe when that object is to be lifted in an upright position as illustrated in Figure 7 on the following page.

The timber hitch is really just a series of modified half hitches. To tie a timber hitch begin by tying a single half hitch around the object as illustrated in Figure 8. Then pass the free end of the rope between the object and rope two more times as shown in Figure 9. Pull the hitch tight by pulling the standing part of the rope at 90 to the object. Then tie one or more half hitches along the length of the object with the standing part of the rope (Figure 10).

Single dutchman (chain knot) The single dutchman (Figure 11) is a very useful knot to use when tying down a load. The knot forms a slipresisting loop which acts like a pulley ina block and tackle system. You can generate almost three times as much tension on a rope using the single dutchman as you would if you just pulled on a straight rope. To tie the single dutchman, form a loop on the standing part of the rope approximately one metre (3 from the second point of anchorage. Take a bight on the rope end and pull it through the loop as illustrated in Figure 12 (on the following page).
1 )

Ti ghten the knot by pulling on both the bight which you pulled through the loop and the free end of the rope. Both the bight and the free end are pulled away from the standing part of the rope. To use the single dutchman as a pulley, you must first pass the end of the rope around its point of anchorage, then pass it through the poi nt of the loop formed by the single dutchman and finally pull the end back towards the poi nt of anchorage to apply tension to the standing part of the rope. When sufficient tension has been applied you can make the knot secure by tyi ng a half hitch or two just below the loop of the single dutchman as illustrated in Figure 13. To untie the single dutchman you must first remove the rope that passes through the loop. Once the loop is clear, a sharp pull on the free end will untie the knot. Figure 13 Single dutchman in use as a pulley Reef or square knot The reef knot or square knot is used to fasten together two ropes of equal diameter. To tie the knot (which is, strictly speaking, a bend) as illustrated in Figure 14 you simply cross the ends of the ropes and turn one rope around the other. Then cross the ends again and turn one end around the other end, making sure the second turn is done in the opposite direction to the first.

Some people remind themselves how the reef knot is tied by using the fa11owi ng verse: 1eft over right then right over left But regardless of the method you use to remember, be sure that your reef knot has both the standing part and the end of each rope on the same side of the loop formed by the other rope.

The sheet bend is used to attach two ropes of unequal diameters to each other. To tie the sheet bend as shown in Figure 15 you begi n by fonni ng a loop or eye with the larger diameter rope. Then pass the end of the smaller diameter rope up through the loop, around the back of the end and standi ng part of the larger rope, and then under the section of the smaller rope where it first came through the loop. Continue with the small end until it lies acros s the top or face of the loop formed by the larger rope. Hold both the standing part and the end of one rope in each hand and pull in opposite directions to tighten the sheet bend.

The carrick bend is used to join two large diameter ropes together. Ropes which are too large in diameter and too stiff for other knots can be joined using the carrick bend.

Figure 16 illustrates how the carrick bend is tied. Fi rst, form a loop with one rope by passing its end under its standi ng part. Pass the end of the second rope under both sides of the loop, over the standing part of the firstrope, under the end of the first rope, down through the loop, under the second rope and then back up through the loop. Both ends should project approximate1y 10 to 20 rope diameters, as the carrick bend tends to slip a considerable amount when tension is first applied to it. If the ropes are pulled taut, the carrick bend will tighten and end up as illustrated in Figure 17. To untie the carrick bend, push the loops of the bend toward the standing parts of each rope. To make it easier to untie the carrick bend, some riggers prefer to tie the end of each rope to its standi ng part with seizing (twine or small rope) before tens ion is app 1 ied. Seizing the ends as illustrated in Figure 18 will prevent the ropes from jamming tightly together.

Figure 16 Tying a carrick bend

I~al I~I

Figure 18 Seizing the ends of a carrick bend

View the videotape, Knot Tying. Practice tying the knots demonstrated.

Now complete Self Test 3 and check your

Choose the best answer for the following questions.

1.

Which of the knots listed below forms a non-slip loop? a. b. c. d. square knot bowline reef knot timber hitch

2.

The knot, hitch or bend illustrated in Figure 1

is a

a. b. c. d.

carrick bend timber hitch clove hitch single dutchman

3.

The knot which multiplies the tension you apply to a rope is the a. b. c. d. timber hitch bowl ine sheet bend single dutchman

4.

If you had to join a large diameter rope to a small diameter rope you would use a a. b. c. d. square knot carrick bend sheet bend ha1f hitch

a. b. c. d.

double half hitch carrick bend sheet bend timber hitch

6.

Fastening wi th a a. b. c. d.

two ropes of equal diameter

to each other is accomplished

square knot sheet bend half hitch clove hi tch

Answers

1'1 I
~

are on page 28.

Now complete the Written

hi tches
II

.lIP

IThen proceed to the Practical Competency on page 29.

ready for evaluation
t

inform your instructor.

Answer Sheet
Self Test 1 - pages 8-10 1. c. Number 1 grade 2. 3. 4.
5.

b. a. c. a. b. d. b. b. a. c. d. a. d.

coarser in texture Number 1 grade polyester nylon polypropyl ene 40% its original length polypropyl ene polypropyl ene sisal 10 960 1bs. 600 lbs. 600 lbs.

6. 7.
8.

9. 10. 11. 12. 13. 14.

Self Test 2 1.

pages 14-16

a. d. b. c. d.

pull it from the inside of the coil pull the twine through beeswax half the rope diameter one and one half rope diameters heat to melt the fibres

2. 3. 4. 5.

H-1 ANSWER SHEET

6.

b. a. d. b.

in a clockwise direction well ventilated la rge in diameter abrasive one fifth its breaking strength dry
50%

7.
8. 9.

10. c. 11. 12. d. c.

Self Test 3 1.

pages 25-26

b. c. d. c. b. a.

bowline clove hitch single dutchman sheet bend carrick bend square knot

2.
3. 4.

5.
6.

Practical Competency 1: Tie knots, bends and hitches

Equipment

Contact your instructor and make arrangements to complete this Practical Competency. 2. 3. Read the checklist on page 30 to identify how your performance will be evaluated. Demonstrate tying knots, bends and hitches as directed by your instructor. Ask your instructor to evaluate each knot, bend and hitch you tie.

Checklist 1: Tie knots, bends and hitches

,
I

STUDENT'S NAME STUDENT'S 1.D. #

DATE: ATTEMPT: 1 2 3 4

1. 2. 3. 4. 5.

Chose correct rope for knot, bend or hitch tied. Specified the knot being tied. Tied knot correctly. Tied knot in reasonable time (no more than 1 minute). Gave verbal account of the application of the particular knot tied.

Instructor's Signature

-------------

Competency H-2 Select Lifting and Hoisting Equipment

Learning Task 1: fork 1 ifts

Select hoists, cranes and 33

39

of loads

41
43

Learni ng Task 3: Select wire ropes and chains Self Test 3 Learni ng Task 4: Sel f Test 4 Select rigging attachments
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

45
52

54
68

Learning Task 5: Determine safe working loads Self Test 5 Learning Task 6: Describe the care and maintenance of slings, straps and hitches
Self Test 6

71
76

78
80

Requirements
Learning Tasks Lifting and hoisting equipment is used in practically every trade area from electrical to carpentry to mechanics. Some hoisting equipment (the chain hoist for example) is found most often in a mechanics shop, while others, like the forklift, are most commonly used in the lumber industry. And, of course, you expect to see big boom and tower cranes on any big construction project. Big cranes are also used in heavy duty mechanics shops to assemble the huge power shovels and scrapers needed in the mining industry. When you have completed the learning tasks in this competency, you should be able to: select the correct lifting equipment to use for a given lifting task, estimate the approximate mass of a variety of loads, determine the safe working loads for certain rigging, identify rigging attachments and accessories and state their uses, and describe how to care for and maintain rigging attachments.

Competencies WRITTEN: "Select lifting and hoisting equipment" You will be tested on your knowledge of: the equipment used in industry to lift, hoist and move loads; the rigging attachments used with this equipment; how to estimate the mass of various loads; wire ropes; chains; and the care and maintenance of lifting equipment and its accessories. You must achieve at least 80% on this Written Competency.

Learning Task 1: Select hoists, cranes and forklifts

Whenever you need to move items which are too heavy or too awkward to move by hand, you must choose which type of lifting apparatus is best suited to the task. To make an intelligent choice, you must know the characteristics of the available equipment.

Hoists are lifting devices which move loads either up and down or sideways, but never both at the same time. Chai n hoists, as illustrated in Figure 1, are most often used for vertical lifts but can be used for horizontal pulls. They are hand operated and are available in a variety of capacities from 450 kg to 9000 kg (1/2 ton to 10 tons). A chain hoist's capacity should be clearly marked and never exceeded. Movement of the load is slow, and distance per lift is limited by the length of the lifting chain.

ENDLESS BEARING

HAND CHAIN

Lifting is achieved by means of an endless hand chain which turns the drive pulley. The drive pulley is connected to the lifting chain by a series of reduction gears which multiply the amount of force the operator exerts on the hand chain. See Figure 2 for a simplified diagram of an endless hand chain hoist. Figure 2 Endless hand chain hoist

To lower loads with a chain hoist you simply pull the hand chain in the opposite direction. Come-along Come-alongs (see Figure 3) are similar to chain hoists except that they are activated by a ratchet 1ever rather than an endless chain. Come-alongs are more convenient for horizontal pulls than chain hoi sts are, and usually have a smaller capacity than chain hoists. As with chain hoists, their capacity should be clearly marked and never exceeded.

A block and tackle is another means of multiplying your power to lift or pull. Synthetic or natural fibre rope is threaded through a number of pulleys to provide a mechanical advantage. To quickly determine the mechanical advantage gained, either count the number of ropes leaving the travelling block or count the number of pulleys. The block and tackle illustrated in Figure 4 provides a mechanical advantage of two while the one in Figure 5 provides a power gain of four. For example, with the block and tackl e in Figure 5, you coul d lift 1000 kg by exerting a force of only 250 kg. The point of attachment for the rope to the upper sheave is known as a becket. A metal thimble shoul d be used at the becket to reduce the stresses developed on the rope when it is bent around a small diameter. Most block and tackle arrangements have no built-in braking system. Therefore, they are not well suited for supporting loads over extended periods unless the load line can be anchored.

Tirfor jacks Tirfor jacks, as illustrated in Figure 6, are hand operated lifting or pulling devices which have an unlimited amount of rope travel. They are operated by a removable pipe handle which raises the load when attached at point A, and lowers it when attached at point B. Tirfor jacks creep along a special wire rope by the IIto-and-fro action of the handle. They can be attached directly to the load as in Figure 7, or they can be anchored near the ground as in Figure 8.
ll

Figure 6 Tirfor jack

The location of the tirfor jack illustrated in Figure 8 provides more comfort and safety to the operator than if it were mounted above the load. You should always try to position the tirfor jack so that you will not be harmed should the load drop. Tirfor jacks are available in three sizes: 750 kg (1600 lbs.) capacity, 1600 kg (3500 lbs.) capacity and 3200 kg (7000 lbs.) capacity. All tirfor jacks are built with an overload protection which consists of a shear pin which breaks when the load weight has been exceeded, preventing further movement of the load.

Forklifts are used to lift and move loads which are stacked on pallets or dunnage (blocks). Motorized fork1ifts, as illustrated in Figure 9, may be powered by electri city or by an internal combustion engine. Their size is determined by the weight they can lift. Motorized forklifts are recommended for lifting and transporting materials which can be stacked on pallets and on each other. Manual forklifts, or pallet trucks as they are often called, are hand propelled units which can lift and move palleted loads which are resting on a smooth floor.

FORK

They cannot be used to stack loads one on top of the other, as their maximum lift is 150 mm to 200 mm (6" to 8") above the floor. They have small steel wheels under the forks and therefore require smooth floors to travel on when loaded. The manual forklift shown in Figure 10 uses a hydraulic jack which is operated by pumping the handle to raise the forks. Travel is accomplished by pushing or pulling, and loads can be gently lowered to the floor by a control at the handle.

Cranes are lifting devices which make use of a live line (one which can be shortened or extended) and a hook which is attached above the load. Cranes can be as simple as the Gantry A-Frame crane illustrated in Figure 11, or as large as the boom crane (illustrated in Figure 12), which is capable of lifting many tons several hundred feet into the air.

Figure 11 Gantry A-frame crane

Cranes such as the one shown in Figure 13 can be moved quickly from one job to another and can be set up in a matter of minutes. An extendable boom and rubber-tired wheels make these cranes truly mobile.

Tower cranes (shown in Figure 14) are used to assist in the construction of high rises. These cranes are used to transport materi al s from the ground to the upper floors and to re-locate 1arge forms from the lower 1 eve 1 s. As the bui 1 di ng increases in hei ght, the crane is raised, allowing it to be used regardless of the height of the stru ctu re .

...

I~I

Now complete Self Test 1 and check your answers.

Self Test 1
Choose the best answer for the following questions. 1. If a pull of 50 lbs. were applied to the lead line in Figure 1, what lifting power would be exerted on the load (disregarding friction)? a. b. c. d. 2. 250 1bs. 2000 lbs. 25001bs. 3000 lbs.

An apparatus capable of long, continuous lifts is the a. b. c. d. chain hoist come-along pallet truck tirfor jack

Figure 1

3.

Forklifts are best suited for lifting and moving loads which are a. b. c. d. bundled on pallets narrow and tall tied with a sling

4.

A crane which is used during the construction of a high rise is the a. b. c. d. tower crane gantry crane boom crane telescopi ng crane

5.

Tirfor jacks can be made to travel in the opposite direction by a. b. c. d. flipping the gear lever turning the handle in the opposite direction releasing the ratchet re-locating the handle

6.

Cranes which have rubber-tired wheels and an extendable boom are popular because they are a. b. c. d. mobile safer than other types of cranes immune to electrical shocks able to transport loads over great distances

7.

If you overload a tirfor jack you will cause its shear pin to break resulting in a. b. c. d. the load dropping the handle jamming a warning light flashing all load movement ceasing

8.

Hand operated forkl ifts can raise loads to a maximum of a. 50 mm (2") b. 200 mm (8") c. 2 m (6 -0") d. their own height
1

Learning Task 2: Determine the approximate mass of loads

The first step in any lifting operation is to determine the approximate mass or weight of the load to be lifted. All decisions such as which equipment to use, the best rigging to use, and the best way ~o secure the load for lifting will be influenced by the 10ad1s mass.

[JJ

Because safe working loads are calculated using imperial measurements, the mass or weight of loads will also be calculated in imperial measurements.

If the load to be hoisted is a manufactured item you may find its mass listed on its identification plate or in its installation instructions. However, if this information is not listed in either of the places, then you must calculate the approximate mass of the load. Some basic weights to remember are: Steel: Dry wood: Wet or green wood: Concrete: Water:
1 1 1 1 1 1

foot square by 1 inch thick. cubic foot ................. cubic foot ................. cubic yard ................. cubic foot ................. gallon .....................

= = = = = =

40 30 50 4000 60 10

pounds pounds pounds pounds pounds pounds

Using these weights you should be able to calculate the mass of most loads by first converting the 10ad1s components into cubic shapes which closely match those of the above table. For example, items made of steel require that you convert their shape into units 1 inch thick and 1 foot square. A sheet of steel plate 1/4" thick measuring 41-0 x 8'_0" is calculated as follows:
11

- x 4x 8

1 4

An angl e iron 3" x 6 X 3/8" x 20 -0" is mentally flattened out as illustrated in Figure 1, then calculated as follows:
9 inches

11

= -3 feet 4

3 x 20 x 3 5.625 x 40

4 x 8 = 5.625

225 1bs.

Round objects such as pipes are calculated in a similar way. First you mentally unroll the pipe into a flat shape. For example, a pipe 1 -0" in diameter, 12 -0" long, made of 3/16" steel plate will need its circumference converted to a flat surface.
1 1

Circumference = diameter x Circumference = 1 x 3.1416 Circumference = 3.1416 feet 3.1416 x 12 x 3 = 7.0686 16 7.0686 x 40 = 282.744 pounds
7C

Items made of wood require their shape to be converted to cubic feet while items made of concrete need to be converted to cubic yards. Any material not listed in the table of basic weights may be included with the material it most closely matches. For example, plywood can be calculated as dry wood. Gravel or sand weighs approximately the same as concrete. Most liquids can be calculated using the weight of water as their weight.

[I]
;;{

If you are not sure about the unit weight of a product, you are better to overestimate its weight than to underestimate it.

Those of you not familiar with imperial measurements may find the following table useful. 1 cubic yard = 27 cubic feet (3 x 3 x 3) 1 cubic foot = 1728 cubic inches (12 x 12 x 12) 1 square foot = 144 square inches (12 x 12) 1 square foot by 1 inch thick = 144 cubic inches (12 x 12 x 1) 1 yard = 3 feet 1 foot = 12 inches Now complete Self Test 2 and check your answers.

I~'

Self Test 2
Choose the best answer for the following questions. 1. The weight of one cubic foot of water is equal to a. b. c.
d.

30lbs. 40 1bs. 50lbs.

60 1bs.

2.

The weight of concrete is based on a. b. c. d. one the the the foot squa re by 1 inch thick cubic foot cubic yard imperi al gallon

3.

Which of the following units is the weight of steel based upon? a. a cubic inch b. one foot square by one inch thick c. a cubic foot d. one square inch by one foot by length Which of the weights below matches the approximate mass of 16 feet of steel beam as illustrated in Figure I? a. b. c. d. 200 lbs. 400 lbs. 3200 1 bs. 4800lbs.
X

4.

5.

33' -0" is

The approximate mass of a concrete wall which measure 6" x 6 -0"

1

a. b. c. d.

3960lbs. 14 667 1 bs. 176 000 lbs. 475 200 lbs.

a. b. c. d.

400lbs. 1080 lbs. 2000 1bs. 4000lbs.

a. b. c. d.

20lbs. 30 1bs. 40 lbs. 50lbs.

a. b. c. d. 9.

30lbs. 40 1bs. 50 lbs. 60lbs. of green lumber which measures

What is the approximate weight of a lift 41-0" x 3'-0" x 141_O"? a. b. c. d. 5040 1bs. 6720lbs. 8400 1bs. 10 080 lbs.

10.

Approximately how heavy is a steel pipe 1 1/21 in diameter, 30'-0" long and 1 1/4" thick? a. b. c. d. 2250 1bs. 7070 1bs. 22 500 1bs 40 000 lbs.

Learning Task 3: Select wire ropes and chains

Wire ropes There are many types of wire ropes available, each designed for a specific application or use. The manner in which a wire rope is made affects its strength, its flexibility and its resistance to abrasion or crushing. Wire rope identification must include no less than one of each of the following seven variables: The first item on a wire rope's description is its length. Wire rope diameter is given in inches or fractions of an inch. Always measure wire rope diameter at its greatest dimension as illustrated in Figure 1, not as shown in Figure 2.

Figure 1 Correct measuring method

Figure 2

Incorrect measuring method

Wire rope composition is identified in three parts: a. b. c. number of strands number of wires in each strand pattern of the wires in the strand

The composition of the rope illustrated in Figure 3 is expressed as:

The number 6 indicates the number of strands. Most wire ropes are made with six strands but some are available with more than six strands.

The number 19 refers to the number of wires in each strand. For ropes of equal diameters, greater flexibility is achieved by increasing the number of wires in each strand. Usual numbers are: 17,19,21,25,31,36,37,41, and 49. "0rdi nary" refers to the pattern of the wi res in each strand. There are four standard patterns. Ordinary All the wires in each strand are the same diameter (see Figure 4).

Figure 4 Ordinary wire pattern

Figure 5 Seale wire pattern

Seale Wires on the outside of the strand are thicker than those on the inside of the strand. The seale pattern (see Figure 5) provides greater resistance to abrasion than does the ordinary pattern. The thinner wires on the inside are used to increase the strand's flexibility. Warrington Thick and thin wires are alternated, as shown in Figure 6, to provide greater flexibility as well as increased resistance to abrasion.

Figure 6 Warrington wire pattern

Fi 11er

Figure 7 Filler wire pattern

Very thin wires are used to fill the voids between the thicker wires as illustrated in Figure 7. The filler wires prevent the outer wires from crowding into the valleys of the inner wires, making the rope resistant to crushing.

Preformed or non-preformed:

Wire rope mayor may not be preformed. Preformed wire rope (Figure 8) has each wire and each strand bent or moulded to match the shape it will have in the completed rope. As a result, preformed rope can be cut without the end untwisting. Broken wires tend to remain in their position rather than stick out from the rope.

Figure 8 Preformed wire rope

Figure 9

Non-preformed wire rope

Non-preformed rope is made from wire just as it comes from the spool. Wires are twisted to form strands which in turn are twisted to form rope, but the tendency of both the strands and the wire is to return to their straight form as illustrated in Figure 9. The wires used to make wire rope are available in different grades, which affect both the rope1s strength and its wear resistance. The lowest grade of steel used for making wire rope is known as grade 100/110 plow steel. Next is grade 110/120 improved plow steel. This is the lowest grade deemed acceptable for lifting by the W.C.B. The best grade is grade 120/130 special improved plow steel, which is used where maximum rope strength is required. You should note that the stronger the grade of steel used to make wire rope, the less the rope is able to withstand repeated bending. The central core of a wire rope will be one of the following: Fibre Core Fibre cores are made of fibre rope. Most are either sisal or manila but fibre cores may also be of synthetic fibres such as polypropylene or nylon. Fibre cores provide greater flexibility to the wire rope than do other cores but are more easily crushed than other cores.

Independent wire rope core (IWRC) The wire rope core is actually a small wire rope itself. produces good flexibility and resistance to crushing.

It

Steel strand core The core of the wire rope is made from a strand similar to or identical with the strands which make up the balance of the wire rope. It has excellent crush resistance but poor
f 1ex i bil i ty

Armoured core Armoured cores are fibre rope cores wrapped with a layer of wires. They provide better crush resistance but less flexibility than plain fibre cores. All four types of cores affect the wire rope1s flexibility, elasticity and resistance to crushing. Your choice of cores will depend on the purposes for which you intend to use your wi re rope. Lay refers to the direction the wires and the strands are wound to make the rope. Regular lay Regular lay rope has the wires of the strands wound in one direction while the strands of the rope are wound in the opposite direction (Figure 10).

I(

Right regular lay

Left regular lay

Right Lang lay

Left Lang 1ay

Lang lay Ropes with a Lang lay have both the wire and the strands wound in the same direction (Figure 10 on the previous page) . As well, both types of lay are available in either right or left lay. Right lay has the strands wound in a clockwise direction along the length of the rope, while left lay has the strands wound in a counterclockwise direction. A typical wire rope identification tag could read: 1000 ft., 3/4" diameter, 7 x 31 Warrington, preformed, improved plow steel, fibre core, right regular lay.

Chain should only be used for hoisting when no other method of slinging or rigging is available. Unlike wire rope, chain will break without warning. In order for wire rope to fail, several individual wires and strands must break before the load drops. You will hear a "popping" sound which will give you some warning that the rope is breaking. But it only requires one link to break in a chain for the load to drop with no warning at all. Chains are usually only used in hoisting operations when their ability to withstand high temperatures and abrasion is required. Because chains have no elasticity, they are very poor at withstanding shock loads. There are several different grades of chain available, but the only grade acceptable for ove rhead hoi sting is grade A. Each link must bear an "A" stamped into its surface as illustrated in Figure 11.

Chains used as slings should be supplied with a master ring at one end and a hook at the other (Figure 12). Figure 12 Chain with master ring and hook

The large master ring is designed to fit over a crane's main hook. Then either the chain's own hook is hooked directly to the load, or the chai n is wrapped around the load and its hook secured to the master 1ink as shown in Figure 13. vlhen using chain in any hoisting operation you must take care not to impose loads on a twisted or knotted chain. If at all possible, sharp bends shoul d also be avoi ded, as they tend to overload the links at the bend.

Monthly link-by-link inspections of inspect immediately any chain which cracks, bends, twist, chips or cuts in Figure 14 and twists will appear

chains should be done. You should also has sustained a shock load. Check for on each link. Bends may occur as shown as in Figure 15.

Chains tend to show signs of wear at the bearing surfaces of each link. When the amount of wear equals 5% of the link diameter for chains less than 1", or 10% for chai ns over 1", you shoul d stop using the chain for hoisting. Wear will show up as illustrated in Figure 16.

Figure 17 contains a list of the safe working load for various sizes of new chains used as a single vertical sling. (Chain size refers to the diameter of the rod which is used to form each link of the chain.)

MAXIMUM SAFE WORKING LOAD "AN TYPE ALLOY STEEL CHAIN SINGLE VERTICAL SLING Chain Size (Inches)
1/4 3/8 1/2 5/8 3/4 7/8 1 1/8 1/4 3/8 1/2 3/4

Capaci ty (Pounds)
3,250 6,600 11 ,250 16,500 23,000 28,750 38,750 44,500 57,500 67,000 80,000 100,000

1 1 1 1 1

I~J

Now complete Self Test 3 and check your answers.

Choose the best answer for the following questions. 1. The lowest grade of wire rope deemed acceptable for hoisting by the Workers' Compensation Board is known as a. b. c. d. 2. 120/130 speci al improved plow steel high carbon steel 100/110 plow steel 110/120 improved plow steel

When compared to a wire rope with an independent wire rope core, a wire rope with a fibre core will be a. b. c. d. stronger more crush resistant more flexible stiffer

3.

If the wires and the strands of a rope are wound in the same direction the rope is said to be a/an a. b. c. d. Lang 1ay rope single wrap rope regular lay rope undi rectional rope

4.

If the strands of wire rope are wound clockwise along its length the rope is said to be a. b. c. d. left handed rope right 1ay rope regu1ar 1ay rope irregular lay rope

5.

The only chain grade deemed acceptable for overhead lifting is grade
a. No. 1

b.
c. d.

A
110/120 improved plow steel H.C.T. (high carbon tempered)

6.

In order for a chain to be acceptable for overhead lifting, the proper grade stamp must be on a. b. c. d. every link one link per foot the master link only the two end links only

7.

Chains less than 111 in diameter should be rejected when they have worn a. b. c. d.
3% 5% 8% 10%

of of of of

their thei r their their

diameter diameter diameter diameter

8.

A wire rope's resistance to wear is increased by using a. b. c. d. an armored core thin wires between each strand larger diameter wires at the surface non-preformed rope

9.

If a single wire on the surface of a wire rope breaks and bends out from the surface of the rope, the rope is said to be a. b. c. d. non-preformed preformed warrington pattern ordinary lay

Learning Task 4: Select rigging attachments

Most items which require hoisting have no provlslons for attaching the load to the device used to lift them. Rigging attachments serve to connect the load to the lifting device. They include the following slings and hardware. To protect both the load and the sling, place padding between the sling and any sharp corners on the load. The simplified diagrams in the following learning tasks do not show the use of such padding, but you must remember to use it in practice. Slings Slings may be made of fibre rope, wire rope, chain or webbing. Slings may be attached to loads in a variety of configurations, each with its own name.

The single vertical hitch consists of leg of sling material with a hook or each end. Eyes on fibre or wire rope lined with thimbles to protect the

a single an eye at should be strands.

Figure 1 Single vertical hitch

Two, three or more legs may be used together to form a bridle hitch (Figure 2).

Bridle hitches are generally used on loads which provide suitable attachment points. The load will be stable if the attachment points are above the load's centre of gravity. When a bridle hitch has more than two 1egs you cannot assume that all legs are shari ng the load equally. Regardless of the total number of legs, the full weight of the load might be shared by only two legs. The other legs may simply be balancing the load as illustrated in Figure 3.

Single basket hitch

Single basket hitches are made from a single length of sling material passed through a load with both ends of the sling then attached to the main hook (Figure 4).

Single basket hitches must not be used on loads which could tilt and slide out of the hitch.

Loads which requi re support from underneath can be lifted with a double basket hitch (Figure 5). The double basket hitch has to be located so that the load is balanced between the two points of support. The two points must also be far enough apart so that the load cannot tip and slide out. Figure 5 Double basket hitch The legs of a double basket hitch should never be inclined less than 60 to the horizontal to prevent the legs from sliding towards each other (Figure 6). By using longer slings you are able to spread the legs further apart without having the legs at an excessively low slope.

60 OR MORE

Figure 6
Double wrap basket hitches

Even loose loads can be securely rigged for hoisting with double basket hitches, if you wrap the sling completely around the load, as illustrated in Figure 7. This double wrapping compresses all the components together, as shown in Figure 8, preventing even the top pieces from sliding out of the rigging.

Single choker hitch

Single choker hitches (illustrated in Figure 9) are made with a single length of sling material hooked back to itself just above the load.

There are several methods of securing one end of the sling back into itself to form the choker, but none will totally secure the top of loose loads (Figure 9-C).

Long loads or loose loads which need to be lifted level may be hoisted with double choker hitches as illustrated in Figure 10.

Double wrap choker hitch

The double wrap choker hitch is similar to the double wrap basket hitch in that both squeeze the load from all sides. Double wrap choker hitches may be used singly or in pairs, as illustrated in Figure 11.

Endless slings

Endless slings (also known as grommet slings) can be used in a variety of configurations as illustrated in Figure 12.

Endless slings are usually made of fibre rope or synthetic webbing. They are light to handle and do not damage the loads, but because they are subjected to sharp bends, they tend to deteriorate more rapidly than do most other types of slings.
Synthetic web slings

Synthetic web slings are available in a variety of shapes and widths. Their relative softness and width protect the loads they are lifting, from being marred or scratched by the sling. The shapes most commonly found are illustrated in Figure 13.

E=====================9

E::~-4

,-=...::::: =:=-.
u

~------------- ------ - -------------~ --___________

Some web slings have metal end fittings instead of sewn eyes. Two types are available. A basket web sling has metal triangles of equal size at each end of the webbing (Figure 14). A choker web sling has a larger triangle containing a slot at one end and a smaller triangle at the other end. The smaller triangle can be passed through the slot of the larger triangle to form a choker hitch (Figure 15).

Figure 14 Basket web sling

Figure 15 Choker web sling

Loads which are too abrasive or too hot for synthetic webbi ng yet require the wide bearing surface of a web belt are rigged with slings made of metal mesh. These meta 1 mes h s1ings are usually equipped with triangle ends which permit the use of either a basket or choker hitch as shown in Figure 16.

Rigging hardware There are occasions when slings alone are not enough to rig a load for lifting. On these occasions you may be required to use some of the following rigging hardware.

Turnbuckles are metal sleeves with left-hand internal threads at one end and right-hand internal threads at the other. Into each end are fitted threaded metal rods (Figure 17).

SLEEVE

LEFT HAND THREAD

The ends of these threaded rods on a turnbuckle are available as eyes, jaws or hooks (Figure 18).

Turnbuckles are used to adjust the lengths of slings so that loads which have uneven attachment points may be lifted in a level position as illustrated in Figure 19.

Figure 19 Adjusting leg length with a turnbuckle Rotation of turnbuckle ends can be caused by vibration or by the application of tension on a twisted rope attached to the
turnbuckle. If there is any chance that

~
~

the ends of the turnbuckles could rotate within the sleeve, the ends should be wi red to the sleeve wi th a lock wi re as illustrated in Figure 20.

jl'iIi\\\UI\

-=====

Figure 20 Turnbuckle end wi th lock wi re

Eye bolts

Eye bolts are used to provide a point of attachment for hoisting. Eye bolts can be shoulderless or shoulder type, as illustrated in Figure 21.

The shoulderless eye bolt is designed for vertical lifts only. If any forces are applied at an angle to the stem of the bolt, the bolt will break as shown in Figure 22.

Shoulder type eye bolts are able to withstand pulls up to 45 from vertical providing the pull is applied along the plane of the eye. Pulling at an angle to the plane of the eye will result in the eye being bent or broken (Figure 23).

Figure 23

Angle of pull on eyebol ts

The safe working loads of eye bolts are given for vertical pulls. When lifting at an angle you must reduce the safe working load of the eye bolt as follows: Vertical 15 from 30 from 45 from over 45 from Pull Vertical Vertical Vertical Vertical

= = = = =

No 45% 65% 75% NOT

reduction in reduction in reduction in reduction in RECOMMENDED

SWL SWL SWL SWL

Shackles (Figure 24) are used to connect a s1ing to a loa d.

Figure 24 There are three basic types of pins available for shackles: screw pins, round pins and safety type pins (Figure 25).

Shackle

Screw Figure 25

Round

Safety

Types of shack 1e pins

Shack 1es shou 1 d be used whenever two or more ropes are to be placed over a hook. The shackle should have a throat large enough to avoid crowding and pinching the ropes (Figure 26). You must never replace the pin of a shackle with an ordinary bolt. Shackle pins are made of hardened steel. Ordinary bolts will bend under load and will damage the shackles.

Shackles can be used to form a choker hitch as illustrated in Figure 27, but you must make sure the pin is not bearing on any moving part of the rope. If the shackle is positioned incorrectly, the rope could cause a screw pin to turn and become loose. Two situations which could cause the screw pin to become loose are illustrated in Figure 28.

Figure 27

Using a shackle for a choker hitch

PACKING

WASHERS

The correct method of attaching a shackle to a lifting hook is illustrated in Figure 29. Note that if the width of the shackle's opening is considerably greater than the thickness of the hook, packing washers should be used to centre the hook on the shackle.

Figure 29

Using packing washers

Choker hooks serve two purposes: they protect the rope from sharp bends and they provide a quick and easy means to tie and untie a choker hitch.

The standard choker hook (Figure 30) is attached to the end of a sling. When the sling is passed around a load, the wi de surface of the choker hook is hooked over the standing part of the sling to form a choker hitch.

Figure 30

Standard choker hook

Figure 31 Adjustable choker hi tch

The adjustable or sliding choker hook (Figure 31) is mounted on a sling which has a loop at each end. The sling is passed around the load and the end loop is hooked over the choker hook. When a choker hitch is not required, the sling shown in Figure 31 can be used as a basket hitch, as a single vertical hitch, or as a bridle hitch used with other slings.

Cable clips are used to fasten the end of a wire rope back onto its standing part to form a loop. Cable clips provide a relatively quick and easy method for tying wire rope. The two most popular types of cable clips are the U-bolt clip and the double saddle clip, illustrated in Figure 32.

Figure 32 Cable clips

65

The Workers' Compensation Board requires that the following regulations must be observed when using cable clips:

Cable clip requirements 54.12. (1) When U-bolt type cable clips are used for fastening wire rope, the U-bolt shall be installed so that it bears on the short or "dead" end of the rope, and the number of clips and their spacing and torque shall be as follows: Diameter of Rope in Inches
1/4 5/16 3/8 7/16 1/2
5/8

Number of Clips
2 2 2 2 3 3 4 4 4 5

Spacing Between Clips Centre to Centre in Inches

1 1/2
2

Torque in ft-lb.
15 30
45 65 65 95

2 1/4 2 1/2
3 4

3/4 7/8
1

4 1/2 5 1/4
6

1 1 1 1
2

1/8 1/4 1/2 3/4

7
8 9

5
6 7 8 8

130 225 225 225 360 360

465

10 1/2

12
13 14

2 1/8 2 1/4

650 650 650

Torque values (2) Where practicable, cable clip nuts or screws shall be torqued to the manufacturer's specifications, or in the absence of such specifications, to the values shown above. Double-saddle clips

(3) Double-saddle type clips shall be used in similar numbers and spacing.

The space between cable clips is usually equal to 6 or 7 rope diameters. The distance from the rope end to the first cable clip should also equal 6 or 7 rope diameters.

Wire rope has a tendency to stretch a small amount when first put into service. Wire rope reduces in diameter as it stretches; therefore, each cable clip wire should be retightened after the first hour of service in a new connection. If the cable clip connection is under heavy strain you should check the tightness of the nuts at regular intervals until no change in their tightness is observed. The correct procedure for installing cable clips is as follows: 1. Calculate the length required for the loop (number of clips required times 6 rope diameters). Install the first clip 6 rope diameters from the rope end as illustrated in Figure 33. Tighten the nuts to the recommended torque using a torque wrench.

Figure 33 2.

Installing first cable clip

Install the second clip as near the thimble as possible (Figure 34). Tighten the nuts but do not torque.

Figure 34 3.

Installing second cable clip

Install all other clips at equal spacing, apply tension to the rope, then torque all the nuts (Figure 35).

I~I

Figure 35

Installing centre cable clips

Now complete Self Test 4 and check your answers.

Choose the best answer for the following questions. 1. Long, loose loads should be rigged for lifting with a. b. c. d. 2. an endless sling a pair of double wrap basket hitches a two-legged bridle hitch a double choker hitch

The sling illustrated in Figure 1 is known as a a. b. c. d. basket bucket bridle single hitch hitch hitch vertical hitch

3.

The sling shown in Figure 2 is known

as a

a. b. c. d. 4.

sliding hook hitch single wrap basket hitch choker hitch wrap around hitch

Loads which are subject to surface damage should be rigged with slings made of a. b. c. d. chain wire rope wire mesh webbing

5.

Turnbuckles are used to adjust the length of slings so that loads can be 1ifted a. b. c d. level higher vert i ca 11y from below

6.

The eye bolt illustrated in Figure 3 is known as a a. b. c. d. round eye bolt shou1 der1ess eye bolt long shanked eye bolt washer1ess eye bolt

7.

When several ropes are to be attached to a single hook, you should make the connection to the hook using a a. b. c. d. turnbuck 1e U-bo1t shackle series of cable clips

8.

The standard spacing of cable clips is equal to approximately a. b. c. d. twice their bolt length 6 rope diameters 6 eye diameters twice the wrench width

9.

The U-bo1t part of a cable clip must be installed so it bears on the a. b. c. d. thimble live end of the rope dead end of the rope whippi ng

10. You should retighten the cable clips on a connection after the connection has been in service for one a. b. c. d. minute hour day week

11. The number of cable clips required for a connection depends on the a. b. c. d. 12. diameter of the rope type of clip used mass of the load strength of the rope

Shoulder type eye bolts are able to withstand pulls at an angle no greater than a. b. c. d. 60 60 30 45 to to to to the the the the horizontal vertical side vertical

13. Any pull applied to a shoulderless eye bolt must be aligned with its a. b. c. d. shank eye washer thread pitch

a. b. c. d.

locking threads identical of different diameters left and right handed

15. The web sling illustrated in Figure 4 is known as a/an a. b. c. d. endless sling standard eye sling twisted eye sling bent loop sling

~~.------.... .--@ .__

::~-:::::::::::::::
.

Learning Task 5: Determine safe working loads

The safe working loads of slings must be taken into consideration before attempting any lift. Manufactured slings will have their safe working load listed on a tag. Slings built on the job will have to be calculated as follows: breaking strength 5 (for lifting materials) Safe working loads. of rope To calculate the safe working loads of fibre ropes use the following formula: 1. 2. 3. Change rope diameter to its equivalent in eighths of an inch. Square the numerator of the resulting fraction. Then multiply by the appropriate factor: Nylon factor = 60 Polyester factor = 60 Polypropylene factor = 40 Manila factor = 20 For example, a 1/2 polypropylene rope has a safe working load of:
1/211
11

SWL SWL

= =

4/811

4 x 4 x 40 640 lbs. (for lifting materials)

To calculate the safe working load of wire rope: 1. Express rope diameter in inches and/or fractions of inches.

3. 4.

Multiply by a factor of 8. Express safe working load in imperial tons (2000 lbs.)

The formula for the safe working load of wire rope is then: SWL in tons = rope diameter x rope diameter x 8

SWL SWL

= 1/2 x 1/2 x 8 = 2 tons (or 4000 1bs.) = 3/4 x 3/4 x 8

4 1/2 tons (or 9000 1bs.)

SWL SWL

If you use either fibre rope or wire rope to make slings you must remember that: a knot can reduce the breaking strength of fibre rope by up to 50%, cable clips correctly attached to wire rope reduce its breaking strength by 20%, and sharp corners of a load should be padded to reduce abrasion on the rope. Safe working loads of slings The safe working load of a sling refers to the load which that sling can safely lift while the sling is used as a single vertical hitch (Figure 1). The same sling used in a basket hitch configuration, with each leg held in a vertical position during the lift, doubles the safe working load of the sling. Therefore the safe working load of the sling illustrated in Figure 2 is: SWL = SWL (of single vertical hitch) x 2 Figure 1 Single vertical hitch Figure 2 Basket hitch with vertical legs

However, should the legs of the basket hitch be inclined, as shown in Figure 3, the safe working load is reduced. To calculate the safe working load of an inclined sling you must use the following formula: Figure 3 Basket hitch with inclined legs SWL H = SWL * x L x 2

*(of single vertical hitch)

72

In the formula, H refers to the vertical distance between the hook and the load (Figure 4). L refe rs to the 1ength of the s1ing 1egs (Figure 4).

For example, if the sling shown in Figure 4 has a safe working load rating of 2000 lbs. when used as a single vertical hitch, the distance H is 3', and the length of L is 51, the true safe working load of the sling configuration shown in Figure 4 is: SWL

= SWL

H x - x 2
L

3 = 2000 lbs. x 5 x 2

Two-leg bridle hitches use the same formula as above, provi ding that both 1egs of the bridle hitch are equal in length. The safe working load of the bridle sling shown in Figure 5 is: SWL

SWL x - x 2 Figure 5 Two-leg bridle hi tch

H L

To calculate the SWL of bridle hitches wi th legs of unequal length or with load attachments of unequal height, use the smallest height or length figures as the

L components in the formula.

H = SWL x - x 2 L

Figure 6 Bridle hitch with legs of unequal length In the case of bridle hitches with 3 or more legs, use the same formula as for bridle hitches with only two legs, because you cannot assume that all legs share the load equally. A four leg bridle hitch could have all the weight carried by two legs as illustrated in Figure 7. Figure 7 Bridle hitch with four legs Single choker hitches use a similar formu1a except that the ratio is never less than 3/4. When the choker angle is over 45 (as illustrated in Figure 8), use the formula:
0

SWL

SWL (of single vertical hitch) x 3/4 Figure 8 Choker angle greater than 45
0

If the choker angle is 45 or less, (as shown in Figure 9) use the formula
0

SWL

SWL (of single vertical hitch) x A/B

Figure 9 Choker angle 1ess than 45

0

Chokers are often used in pairs to lift loads in a horizontal position as shown in Figure 10. To calculate the safe working load of such sling configurations use the fol1owi ng formul a: A H SWL x - x - x 2 B L

Double basket hitches are self adjusting in the sense that each leg carries its share of the load. Therefore, to calculate the safe working load of the double basket hitch illustrated in Figure 11, the formula
is:
H = SWL* x - x 4

I~I

Now complete Self Test 5 and check your answers.

Choose the best answer for the following questions. 1. The safe working load for a 3/4" diameter, knotted nylon rope used to lift materials is (Remember to allow 50% strength reduction due to knots.) a. b. c. d. 2. 540 1bs. 10801bs. 1680 1bs. 2160 1bs.

Cable clips reduce the breaking strength of wire rope by a. b. c. d.

10%

20% 30% 40%

3.

How many tons can you safely lift with a wire rope which is 1" in diameter? a. b. c. d. 1 6 8 64 ton tons tons tons

4.

The safe working load of any sling indicates the load it can lift as a a. b. c. d. single double single bridle choker hitch basket hitch vertical hitch hitch

5.

Regardless of how many legs a bridle hitch has, you must calculate its safe working load as if it had only a. b. c. d. one two 3/4 50% leg legs its safe working load of its strength

The formula SWL = SWL x a. b. c. d. 7.

H L

x 4 is only to be used on

double choker hitches any hitch with a double wrap four legged bridle hitches double basket hitches

Calculate the safe working load of the sling arrangment shown in Figure 1 if each sling has an SWL rating of 2000
1bs.

H a. b. c. d.

= 9 feet, L = 12 feet
1500 3000 4000 5333 1bs. 1bs. 1bs. 1bs .

8.

Each individual leg of the sling arrangment in Figure 2 has an SWL rating of 1000 lbs. H = 11 feet, L = 12 feet Calculate the SWL of the sling arrangement in Figure 2. a. b. c. d. 1833 2182 2750 3000 lbs. 1bs. 1bs. 1bs.

9.

The SWL rating of the sling in Figure 3 is 3000 lbs. What is the strongest SWL you could get if you use it in a single choker hitch as shown in Figure 3? a. b. c. d. 1500lbs. 2250 1bs 3000 1bs. 4000lbs.

Learning Task 6: Describe the care and maintenance of slings, straps and hitches
The way slings are used and stored affects how long they will last. Slings which are used to lift the types of loads they were designed to lift, and stored in a clean, dry environment will provide many years of safe service. Slings which are abused may cause you or a fellow worker a very serious injury. For the care and use of all slings, straps and hitches, follow these rules: 1. 2. 3. 4. 5. 6. 7. Do not allow slings to contact corrosive materials. Do not drag slings from under loads. Place loads on dunnage (blocks) to allow easy removal of slings. Never attempt to lift loads heavier than the sling's rating. Never use a sling angle less than 45 to the horizontal. Whenever two or more slings are to be attached to a hook, use a shackle between the sling and the hook. Never leave slings lying around where they could be run over by machinery. Use padding to protect the sling from sharp edges of the load or the load from being damaged by the sling.

In the case of slings which are made from wire rope: 1. Avoid sharp bends by placing blocks, corner pad~ or saddles around the sharp corners of a load. The length of the rope which contacts the load at any bend should equal one rope lay. Keep wire rope dry. Do not permit any bending at or near splices or fittings. Do not double wrap a wire rope around a hook. The sharp radius will damage the rope.

2. 3. 4.

To ensure that chain slings will provide years of service: 1. 2. 3. 4. Never shorten a chain by twisting or knotting. Avoid impact or shock loading. Do not try to repair chain which is used for hoisting. worn sections must be repaired by a specialist. Damaged or

If at all possible, always hook the chain back to the master link.

In the case of slings made from synthetic webbing: 1. Protect these web slings from welding and flame-cutting operations. Temperatures above 94C (200F) will damage synthetic slings. Store synthetic slings out of direct sunlight. to sunlight will cause damage. Prolonged exposure

2. 3.

Keep synthetic slings away from all contact with acids.

I~J

Now complete Self Test 6 and check your answers.

Self Test 6
Choose the best answer for the following questions. 1. Whenever use a/an two or more slings are to be attached at the hook, you should a. b. c. d. 2. turnbuckle eye bolt double hook shackle

The angle fonned by a sling and the horizontal should never be less than a. b. c. d.
300 450 600 750

3.

To ease the removal of slings from under a load you should a. b. c. d. grease the slings set the load on dunnage place the load on soft soil pull them out with the crane

4.

Chains which are used for hoisting should be repaired by a. b. c. d. a wel der anyone using special repair links a specialist

5.

Wire rope slings should be prevented from slipping on a hook by double wrapping the hook. a. b. true false

6.

Prolonged exposure to direct sunlight is harmful to slings made of a. b. c. d. wire rope chain synthetic webbing steel mesh

7.

Synthetic web slings should not be subjected to temperatures above a. b. c. d. 66C 94C 149C 260C (150F) (200F) (300F) (500F)

't'

hoisting equipment".

Now complete the Written

Competency H-2, "Select

lifting

and

Answer Sheet
Self Test 1 1.

pages 39-40

a. d. b. a. d. a. d. b.

250 lbs. tirfor jack on pallets tower crane re-locating the handle mobil e all load movement ceasing 200 mm (8")

2. 3. 4. 5. 6. 7. 8.

Self Test 2 1.

pages 43-44

d. c. b. b. b. d. b. c. c.

60 1bs. the cubic y~rd one foot square by one inch thick 400 lbs. 14,667 lbs. 4000 1 bs. 30 lbs. 50 1bs. 8400 lbs. 7070 1 bs

2. 3. 4. 5. 6. 7. 8.
9.

10. b.

Self Test 3 1. 2. 3. 4.
5.

pages 52-53

d. c. a. b.
b.

110/120 improved plow steel more flexible lang lay rope right lay rope
A

6.

a.

eve ry 1 i nk 5% of thei r diameter larger diameter wires at the surface non-preformed

7. 8. 9.

b. c. a.

Self Test 4 I.

pages 68-70

b. d. c. d. a. b. c. b. c.

a pair of double wrap basket hitches single vertical hitch choker hitch webbing
1eve 1

2.
3.

4. 5. 6. 7.
8. 9.

shoulderless eye bolt shackle 6 rope diameters dead end of the rope hour diameter of the rope 45 to the vertical

10. b.
II. a.

12. d.

13.

a.

shank left and right handed a twisted eye sling

14. d. 15. c.

Self Test 5 l.

pages 76-77

b. b. c. c. b. d. b. a. b.

1080 lbs. 20% 8 tons single vertical hitch two legs double basket hitches 3000 lbs. 1833 1 bs. 2250 lbs.

2. 3. 4. 5.
6.

7. 8. 9.

Self Test 6 l.

pages 80-81

d. b. b. d. b. c. b.

shackle 45 set the load on dunnage a specialist false synthetic webbing 94C (200F)

2. 3. 4. 5.
6.

7.

competency H-3 Lift, Hoist and Move Loads

sign a1 s
Self Test 1

89 94

Learning Task 2: Describe safe procedures for lifting, hoisting and moving loads .......
Self Test 2

97
101

Checklists: Lift, hoist and move loads A: Demonstrate hand signals ..... 108
B: Use a crane 109

C: Use a motorized forklift ..... 110 D: Use a manual forklift ....... 111 E: Use a hoist 112

Requirements
Learning Tasks To lift, hoist and move loads which are too heavy to lift by hand you must use some form of lifting machinery. Very often the process involves more than one person: one to operate the machine and one or more to guide the load into place. Sound or visual signals are used to allow the people involved to communicate. If you are one of the people involved in hoisting you will need to take an active part in the signalling. Even if you are not directly involved with giving signals, you must be able to understand each signal so that you can anticipate the movement of the load. When you have completed the learning tasks in this competency, you should be able to: identify sound and light signals, identify hand signals, describe the correct use of forklifts, describe the safety requirements for working around cranes, describe the correct use of hand powered hoists,

Competencies

You will be tested on your knowledge of the current procedures for using lifting equipment and on your ability to identify sound and visual signals used around lifting equipment.

PRACTICAL:

You will be required to demonstrate hand signals. You will also be required to lift, hoist and move loads using equipment selected by your instructor. You must achieve 100% on Practical Competency A, IIDemonstrate hand signals and at least 80% on each additional segment of the practical competency that you are required to complete.
ll ,

You will need to refer to the following resource. VIDEOTAPE: The Colour of Danger

Learning Task 1: Identify sound and visual signals

Whenever the operator of lifting or hoisting equipment is unable to obtain a clear view of the path of the load or of the path of the equipment, a competent signaller must be stationed to get a clear view of the operation and the operator. That signaller must direct all movements of the load from this vantage point.

Sound or light signals When the lifting apparatus is a hoist capable of moving only up or down and not sideways, the only signals used are "RAISE", "LOWER", "STOP" and "ALL CLEAR".

[I]

Hoists of this kind generally have safety gates on them which, when open, prevent operation of the hoist. Nevertheless, a hoist operator must not operate the hoist until the "ALL CLEAR" signal has been given.

The "ALL CLEAR" signal is an indication that the workers using the hoist are finished with it, and that the hoist operator can now operate it again safely. Since the operator lers, a system of sound signals are signals are short of such a hoist may not always be able to see the signalsound signals or light signals has been devised. The short bursts from a horn or rings of a bell and the light flashes from a light source. Both use the same code: "STOP" "RAISE" "LOWER" "ALL CLEAR" one bell or flash two bells or flashes three bells or flashes four bells or flashes

During adverse conditions both light and sound signals may be used at the same time. An easy way to memorize sound or light signals is to consider the urgency of each signal. There is no urgency attached to the signal "ALL CLEAR"; therefore it is the longest - 4 bells. "STOP", on the other hand, could be an emergency; therefore it is the shortest - 1 bell. "RAISE" coul d have more urgency than "LO~IER" so it requires 2 bells, and "LOWER" is left with the signal 3 bells. The system is very logical when you stop to think about
it.

Hand signals Cranes which are capable of more than just up and down movement of their hook are controlled by the following hand signals:

With your forearm vertical and your forefinger pointing up, move your hand in small horizontal circles.
To signal "LOWER"

With your forearm extended downward and your forefinger pointing down, move your hand in small horizontal circles.

If both your hands are free, extend both arms horizontally with your fingers outstretched. If only one hand is free, you signal "STOP" by facing the palm of your hand toward the operator with your fingers outstretched and waving your hand from side to side.

Boom signals

See the illustration of a crane on page 92 for a picture of a boom. Raising or lowering the boom is signalled with the arm extended, the fingers closed, and the thumb indicating whether you want the boom raised or lowered.

Cranes which are equipped with an extendable boom can be signalled to lengthen or shorten the boom. You do this by holding your fists in front of your body and pointing in or out with your thumbs.

These signals may be done with only one hand when required.

To signal the crane operator to swing the boom, extend one arm and point with the index finger to indicate the direction of swing.

Dual motions can be signalled to the crane operator. You can signal the operator to lower the boom while raising the load (which causes the load to move away from the crane), or to raise the boom while lowering the load (which moves the load closer to the crane). You can do this with one or both hands. When you are using only one hand, your thumb indicates the direction of the boom, and flexing your fingers indicates the movement of the hook.

I~

Line signals

As illustrated at the right, cranes are sometimes equipped with a jib to extend the crane's reach. From th is jib a whip line or auxiliary hoist is attached while the main line is suspended from the boom.

WHIP LINE

[I]

The whip line should only be used for very 1ight loads.

The following signals indicate to the crane operator which line to use.
1.

To signal the operator to use the main line, tap your fist to your head. Then use regular signals to direct further motion. To signal the operator to use the whip line, tap your elbow with one hand or point to your shoulder. Then use regular signals to direct further motion.

2.

Whenever slo\'1movement is required, you hold the palm of your free hand motionless in front of your other hand as it is giving the signal. The figure to the right shows the signal for "HOIST SLOWLY".

The "DOG EVERYTHI NG" signal is given by claspi ng your hands in front of your body. The crane operator locks all crane functions at this signal.

[)J

These signals should be practiced until they become almost automatic to you. They are used by all trades which are involved with lifting or hoisting operations, and they are often used by workers to communicate with the crane signaller.

I"

Now do Self Test 1 and cloeck your answers.

CD

1.

Match the figures above to the signals listed on pages 94 and 95. A. "USE THE MAIN LINE"

Choose the best answer for the following questions. 2. The sound or light signal for IILOWERII is a. b. c. d.
3.

one bell or flash two bell s or flashes three bells or flashes four bells or flashes

The sound or light signal for IISTOPII is a. b.

c.

d. 4.

one bell or flash two bells or flashes three bells or flashes four bells or flashes

The sound or light signal for IIALLCLEARII is a. b. c. one bell or flash two bells or flashes three bells or flashes four bells or flashes

d.

a. b. c. d.

one bell or flash two bells or flashes three bells or flashes four bells or flashes

Learning Task 2: Describe safe procedures for lifting, hoisting and moving loads
The first and most important step in any 1ifting operati on is to determi ne the mass of the load as you learned to do in Competency H-2. The second step is to select the appropriate equipment for the lift. You must make sure the weight of the load does not exceed the capacity of the equipment selected. Each make and model of lifting equipment will have its own particular requirements. However, there are some general rules which should always be observed when operating or working around the following equipment.

Hand-operated forklifts Hand-operated forklifts or pallet trucks are relatively safe to operate providing you observe these rules: 1. 2. 3. 4. 5. 6. 7. Make sure the load is balanced on the pallet. Loose loads should be secured with strapping before being moved. Lift loads carefully, making sure the load is not interlocked with adjacent loads. Travel at a pace that allows you total control of the load. When pulling a load backwards, pay attention to what's behind and beneath you.
00 not lower a load unless you are certain that feet and fingers are clear of the load.

Store a pallet truck so that its forks and handle are out of heavily travelled areas.

Motorized forklifts steer with their rear wheels, which causes the back of the forklift to swing wide on turns. You must keep the front wheels crowded to the inside of a turn if you are operating in a confined area.

Forward and reverse motions are controlled by a clutch, gear lever and throttle. A foot operated brake is used for slowing and stopping while a hand brake is used to prevent wheel movement once parked. The lift forks and carrier assembly are usually controlled by the following 1evers. A. B. Pulling back on the fork control lever causes the forks to rise. Pushing the same lever ahead causes the forks to move down. Pulling back on the tilt control lever causes the entire fork assembly to tilt the load towards the forklift. Pushing the tilt control lever forward will cause the load to tilt away from the operator. A third lever is found on those forklifts equipped with a sideshifting fork assembly. By pushing or pulling on this lever you cause the load to move either to the left or the right. Some forkl ifts are controll ed differently from the above description. Before using any unfamiliar motorized forklift, check how the controls work with your instructor or a knowledgeable operator.

c.

[j] 11\
2. 3. 4. 5. 6. 7. 8.

When using the forklift to lift and transport loads you should observe the following rules.

Single unit loads must not project more than half their height above the fork carriage. Loose loads must not project above the fork carriage. Wide high loads which block the driver's view should be transported with the load trailing. Position all loads as near the fork carriage as possible. Transport loads with the load tilted back (towards the forkl ift). When you are moving a load up or down a ramp, the load must always face the top of the ramp. All turns must be made on level surfaces. Never turn a forklift on a sloping surface. You risk tipping the load, the forklift or both.

9. Avoid quick or jerky starts and stops.

10. Slow down for all turns. When parking the forklift, park away from heavily travelled areas. Set the parking brake and lower the forks to the ground before leaving the machine. Never lift or carry personnel on a forklift. View the videotape, The Colour of Danger, for information on fork 1ift safety.

Large cranes are usually operated by trained personnel. However, you may be required to rig loads for lifting, to direct crane movements using signals and to position loads as they are lowered into place by such cranes. To lift, hoist and move loads using a crane requires that you observe the following precautions.
1.

Never allow the load to travel above personnel, including yourself. Do not attempt lifts in high winds. The load can act like a kite and shift sideways unexpectedly. Always ensure that the hoist line is plumb when picking up a load. Never pull sideways with a boom crane. When calculating loads, do not forget to include the weight of all the rigging equipment which will be lifted by the crane. Use a tag line (see Figure 1) on all loads. Tag lines permi t you to control the rotation of a load without endangering yourself should the load drop.

2. 3. 4. 5.

Forward and reverse motions are controlled by a clutch, gear lever and throttle. A foot operated brake is used for slowing and stopping while a hand brake is used to prevent wheel movement once parked. The lift forks and carrier assembly are usually controlled by the following 1evers. A. B. Pulling back on the fork control lever causes the forks to rise. Pushing the same lever ahead causes the forks to move down. Pulling back on the tilt control lever causes the entire fork assembly to tilt the load towards the forklift. Pushing the tilt control lever forward will cause the load to tilt away from the operator. A third lever is found on those forklifts equipped with a sideshifting fork assembly. By pushing or pulling on this lever you cause the load to move either to the left or the right. Some forklifts are controlled differently from the above description. Before using any unfamiliar motorized forklift, check how the controls work with your instructor or a knowledgeable operator.

c.

[i]
~ 2. 3. 4.

When using the forklift to lift and transport loads you should observe the fo11owing rules.

Single unit loads must not project more than half their height above the fork carriage. Loose loads must not project above the fork carriage. Wide high loads which block the driver's view should be transported with the load trailing.

6. 7. 8.

Transport loads with the load tilted back (towards the forklift). When you are moving a load up or down a ramp, the load must always face the top of the ramp. All turns must be made on level surfaces. Never turn a forklift on a sloping surface. You risk tipping the load, the forklift or both.

6.

Wear leather gloves when handling wire rope slings. Broken wires are needle sharp and injuries can be very painful.

Hand powered hoists Hand powered hoists include chain hoists, come-alongs, block and tackle arrangements, and tirfor jacks. Whenever you are using any of the above equipment you should observe the followi ng rules. 1. 2. 3. 4. Do not overload the capacity of the equipment. Make sure the rigging is adequate for the load. Never allow any part of your body to be under the load. Always be prepared to react in case the load should drop. Check all parts of the equipment frequently for signs of deterioration or wear.

A hardhat, gloves and safety-toed boots are essential. The most important safety rule to remember is, "stay alert!" Most accidents can be avoided if people keep their eyes and their minds on what they are doing.

IZINOW

do

Choose the best answer for the following questions. 1. The first step in any lifting or hoisting operation is to a. b. c. d. 2. check the slings remove all crating material decide which piece of lifting equipment to use determine the mass of the load

A forklift transporting a load up or down a ramp or incline should have the load: a. b. c. d. in front trailing on the high side of the slope on the low side of the slope

3.

Forklifts may have loads projecting above their carriage only if the load is a. b. c. d. on level ground not tilted back top heavy a single unit

4.

Your best form of personal protection during lifting or hoisting operations is a. b. c. d. a hardhat being alert safety-toed boots a pair of gloves

a. b. c. d.

slow down the speed of the forklift assist the foot brake on steep slopes lower the load slowly prevent wheel movement when parked

6.

During transport with a motorized forklift the loads should be a. b. c. d. tilted toward the forklift lifted above the operator1s line of sight tilted in the direction being travelled secured with the correct sling configuration

7.

The load being transported by a forklift must be trailing if it a. b. c. d. is travelling up a sloping ramp blocks the operator's view is half as high as the carriage is made up of loose components

8.

When calculating the weight of a load to be picked up by a crane you must include the weight added by the
a.

wi nd

b. c.
d.

length of boom load rigging

jib

9.

Whenever you are handling wire rope you must be wearing a. b. c. d. eye protection a hard hat steel-toed boots leather gloves

Answers are on page 103. Nowcomplete the Written Competency H-3, "Li ft, loads" . hoi stand move

1'1

I~INOW

proceed to the Practical

Competency on page 104.

Answer Sheet
Self Test 1 1.

pages 94-96 H.
1.

A. B.

2, 17
6

c.
D. E. F. G. 2. 3. 4. c. a. d. b.

3 10 14, 15 5

J. K.

1, 12 4 7, 11
8

L.
M.

13 18

three bells or flashes one bell or flash four bells or flashes two bells or flashes

Ju
,

Self Test 2 1. 2.

pages 101-102

d. c. d. b. d. a. b. c. d.

determine the mass of the load on the high side of the slope a single unit being alert prevent wheel movement when parked tilted toward the forklift blocks the operator's load rigging leather gloves view

3. 4. 5.
6. 7.

8.
9.

Practical Competency 1: Lift, hoist and move loads

Equipment lifting equipment rigging equipment

There are several lifting and hoisting activities included in this practical competency. The first, IIDemonstrate hand signals", must be completed by all students. For the others, contact your instructor who will select those lifting and hoisting activities that you will be required to complete. Make the necessary arrangements to attend any required demonstrations on the use of the lifting and hoisting equipment.
A. Demonstrate hand signals

1.

Read the checklist on page 108 to identify how your skill will be evaluated.

Lilz, I~ I
4.

Contact your instructor to make arrangements to demonstrate signals.

Ask your instructor to evaluate your performance.

Practical Competency 1: Lift, hoist and move loads

Equipment

safety footwear (steel-toed boots) leather gloves

There are several lifting and hoisting activities included in this practical competency. The first, IIDemonstrate hand signal sII,must be compl eted by all students. For the others, contact your instructor who will select those lifting and hoisting activities that you will be required to complete. Make the necessary arrangements to attend any required demonstrations use of the lifting and hoisting equipment.
A. Demonstrate hand signals

on the

1.

Read the checklist on page 108 to identify how your skill will be evaluated.

[il2. I~ I

Contact your instructor to make arrangements to demonstrate signals.

4.

Ask your instructor to evaluate your performance.

.,
L.:l\.1

Contact your instructor to make arrangements to complete this lifting and hoisting activity. Your instructor will direct you to the crane, indicate the load to be lifted and indicate the destination of the load. 2. 3. 4. 5. 6. 7. Read the checklist on page 109 to see how your skills will be evaluated. Determine the weight of the load. Confirm that the weight of the load does not exceed the crane's capaci ty. Select the appropriate rigging (slings, hitches and tag lines). Rig the load for lifting. Signal the crane operator to move the lifting line directly above the load's centre of gravity.

Contact your instructor to make arrangements to complete this lifting and hoisting activity. Your instructor will direct you to the forklift, indicate its load and indicate the destination of the load. 2. Read the checklist on page 110 to identify how your skills will be eval uated.

3.

Perform a visual inspection of the load to determine if it is suitable for transporting with the forklift. If it is, then proceed. If it is not, inform your instructor and state the reasons for your decision. Conduct a visual inspection of the forklift. Notify your instructor of any deficiencies. Check all fluid lvels.

4.

6. 7. 8.

Insert the forks into the pallet. Raise the load approximately 150 mm (6"). Tilt the load towards the forklift.

10. 11. 12.

Lower the load and back the forks out of the pallet. Return the forklift to its parking space. Set the handbrake, lower the forks to the ground, then turn off the forkl ift.

I~
2. 3.

13.

Ask your instructor to evaluate your performance.

Contact your instructor to make arrangements to complete this lifting and hoisting activity. Your instructor will direct you to the pallet truck, indicate its load and indicate the destination of the load. Read the checklist on page 111 to identify how your skills will be evaluated. Conduct a visual inspection of the load to determine if it is suitable for transporting with the pallet truck. If it is then proceed; if not, inform your instructor and state the reasons for your decision.

6. 7.

Move the pallet to its new destination. Lower the load and park the pallet truck in its place of storage.

I~ '8.
2. 3. 4. 5. 6.

Ask your instructor to evaluate your performance.

Contact your instructor to make arrangements to complete this lifting and hoisting activity. Your instructor will direct you to the hoist you are to use and indicate the load you are to lift. Read the checklist on page 112 to identify how your skills will be evaluated. Determine the weight of the load then check the capacity of the hoist to ensure that the equipment is capable of lifting the load. Select the required rigging (slings, hitches, etc.) from their place of storage. Rig the load for lifting. Attach the load to the hoist.

8.

Lower the load and return all equipment to storage.

Ask your instructor to evaluate your performance.

Checklist: Lift, hoist and move loads

A. Demonstrate hand signals

STUDENT'S NAME STUDENT'S I.D. Each item

DATE:

#
1 point.

ATTEMPT:

1 2 3 4

is worth

The student *1. *2. IISTOPII

correctly

demonstrated

the following

hand signals:

IIHOIST AND/OR LOWERTHE LOADII IIRAISE AND/OR LOWERTHE BOOM" IIRETRACT AND/OR EXTEND THE BOOMII IISWING THE BOOMLEFT AND/OR RIGHTII IIUSE THE MAIN LINEII IIUSE THE WHIP LINEII IILOWERTHE BOOMII and IIRAISE THE LOADII (using two hands)

*3.
*4. *5. *6.

*7.
*8.
*9. *10. *11.

IIRAISE THE BOOMII and IILOWERTHE LOADII (usi ng one hand) IIHOIST AND/OR LOWERTHE LOAD SLOWLYII IIDOG EVERYTHINGII

Instructor's

Signature

-------------

Checklist: Lift, hoist and move loads

B. Use a crane

STUDENT'S NAME STUDENT'S 1.D. #

DATE: ATTEMPT: 1 2 3 4

*1. 2. 3. 4. 5. 6. 7. 8. 9.

Correct safety attire worn (hard hatt safety footwear). Approximate weight of load correctly determined. Capacity of equipment checked. Correct rigging selected. Load correctly rigged for lifting. Lifting hook centred above load prior to lifting load. Rigging correctly attached to lifting hook. Correct signals given to crane operator. Load lowered in correct locations.

Instructor's Signature

--------------

Checklist: Lift, hoist and move loads

C. Use a motorized forklift

1 2 3 4

STUDENT'S NAME STUDENT'S 1.0. # Each item is worth 10 points. Mark:

DATE: ATTEMPT:

*1. *2. 3. 4. 5. 6. 7. 8. 9.

Attended demonstration of forklift's controls. Correct safety attire worn (hard hat, safety footwear). Performed visual inspection of load. Determined weight and suitability of load. Performed all necessary inspections of forklift. Correctly positioned forks into pallet. Lifted load to correct height for transporting load. Forks tilted to correct angle for transporting load. Travelled at suitable speed.

10. Lowered pallet into assigned position. 11. Forks correctly extracted from pallet. *12. *13. Forklift parked in designated area. Handbrake set, forks lowered and motor shut off.

Checklist: Lift, hoist and move loads

D. Use a manual forklift

STUDENT' S ~JAME STUDENT'S I.D. #

DATE: ATTEMPT: 1 2 3 4

Each item is worth 10 points. Mark:

*1. 2. 3.

Security of load on pallet checked. Forklift correctly positioned under pallet for lift. Pallet lifted correctly. Pallet safely moved to assigned location.

4.

6.

Forklift moved out from under pallet and parked in designated area.

Checklist: Lift, hoist and move loads

E. Use a hoist

'1.

STUDENT'S NAME STUDENT'S 1.0. #

DATE: ATTEMPT: 1 2 3 4

2. 3. 4. 5. 6. 7.

Approximate weight of load correctly determined. Capaci ty of equipment checked. Correct rigging selected. Load correctly rigged for lifting. Lifting hook centred above load prior to lifting. Rigging correctly attached to lifting hook.

*10.

All rigging returned to storage.

Comments:

-----------------------------------------

Instructor's Signature

Competency H-4 Use Jacks

Learning Task 1: Identify jacks .......... 115 Self Test 1 .................................. 122 Learni ng Task 2: using jacks Self Test 2 Learning Task 3:
of jack s Sel f Test 3

124
126

Describe the care and maintenance

128 132

Practical Competency 1: Use jacks Checklists: Use jacks A: Use screvJ jacks ................. B: Use 1eve1 jacks ................. c: Use scissor jacks ............... 0: Use hydraulic jacks ............. E: Use floor jacks ................. F: Use bumper jacks ................

138 139 140 141 142 143

Requirements
Learning Tasks The jack is invaluable when a task involves lifting heavy loads a short distance. Most trades make use of jacks; so, the information contained in this learning guide will be helpful to you even if you do not need to work with them on a daily basis. When you have completed the learning tasks in this competency, you should be able to: describe the jacks commonly found in industry, describe the uses of each jack, describe the correct procedures for using jacks,

Competencies WRITTEN: "Use jacks" You \dll be tested on your knowledge of jacks used in industry, the intended use of each jack, the correct procedure for using jacks and how to care for and maintain jacks. You must achieve at least 80% on this Written Competency. PRACTICAL: You will be required to use various jacks to lift heavy items. You must achieve at least 80% on the checklist for each jacking project you complete.

~,

All the resources you will require are included in this learning guide.

Learning Task 1: Identify jacks

A jack is a portable hand-operated machine capable of heavy lifts without much force or power being applied by the operator. A jack is usually identified by its size in terms of its capacity, the number of tons it is capable of lifting. Jacks are divided into two basic categories: jacks. mechanical jacks and hydraulic

Mechanical jacks Mechanical jacks gain their mechanical advantage through the use of the screw, the lever, or a combination of both.
Screw jacks

Screw jacks illustrated in (Figures 1 and 2) range in size from 1/2 ton (450 kg) to 50 tons (45 000 kg). Depending on their capacity, screw jacks can be used to raise automobiles, heavy equipment, and large industrial machinery, as well as entire buildings. There are several styles of screw jacks available. Some, like the one in Figure 2, are used in residential construction to support the main floor of the house. As the wood used to frame the floor shrinks, the screw jack at the top of the adjustable post is extended to return the floor to level.

Figure 2

Adjustable post jack

Some screw jacks are operated by turning the large screw-thread at the top. Others are turned by a crank handle through a gear mechanism at the base of the jack. To use the screw jack illustrated in Figure 1 (on the previous page), you must insert the handle into a hole near the top of the screw and turn the screw by rotating the top of the jack with the handle. If space permits, turn the handle in a full circle around the jack. If space is limited, turn the handle as far as possible, relocate the handle in another hole and continue the rotation of the screw.

Lever jacks

Lever jacks (Figures 3 and 4) gain their mechanical advantage through the use of the lever. A ratchet pennits the lifting to take place in small steps. Each time the lever handle is moved through a full stroke the 1ifti ng mechanism either raises or lowers by one notch along the stem of the jack. Lever jacks are available in a wide range of sizes (capacities), lengths and shapes. The jack shown in Figure 3 is rated at 2 tons (1800 kg) and is capable of lifts of up to 4'-011 (1200 mm).

Figure 3 Lever jack (jackall)

The lever jack illustrated in Figure 4 is rated at 5 tons (5080 kg) and can lift objects a distance of 1011 to 11-011 (250 mm to 300 mm). Note that the jack shown in Figure 4 has two lifting points: one at the very top and one near the base.

A lever jack is operated by moving the handle up and down through a full stroke. The distance the jack moves up or down with each full stroke is determined by the spacing of the notches in the upright. A small lever at the side of the jack controls the direction the jack travels. Usually, when the direction lever is pointing up, the jack will travel up and when the direction lever is pointing down, the jack will travel down. A lever jack is generally placed at the perimeter of the object it is lifting rather than underneath it because of the room needed to operate the handle.
Scissor jacks

The sci ssor jack shown in Figure 5 combi nes the use of both the screw and the lever. The lift is activated by turni ng the horizontal screw at the centre of the jack. The levers that provi de the scissor action of the jack also provide a feature unique to thi s jack: as the scissor jack is extended, its mechanical advantage INCREASES. Figure 5 Scissor jack Scissor jacks are light-duty automotive jacks primarily used by vehicle owner/operators. They often come as a standard equipment with mid-size and compact cars. These jacks are usually used to lift only one end of a light duty truck or an automobile. Some lift from under the vehicle axle while others attach to special places under the vehicle's body. Scissor jacks are operated by a crank handle attached to the end of the screw. Whin-you turn the crank handle clockwise you raise the load. Turning the crank handle counterclockwise lowers the load.

Hydraulic jacks

Hydraulic jacks, as their name implies, gain their mechanical advantage through the use of hydraulics. A relatively small pump piston forces oil against a relatively large lifting piston. The mechanical advantage provided depends on the ratio of the pump piston's diameter to the lifting piston's diameter.

Hydraulic jacks range in size from 1 1/2 tons (1360 kg) to 100 tons (90 000 kg). Hydraulic jacks, as illustrated in Figure 6, have a relatively short lifting distance: 3 1/2" to 8" (90 mm to 200 mm). Some hydraulic jacks have an adjustable screw head which can be used to adjust the total length of the jack prior to the start of a lift. Hydraulic jacks can be used for any type of lifting or pressing but they are most useful in situations that require a large lifting capacity rather than the capacity to lift a load to any great height.

Hydraulic detachable and has a the valve

jacks like the one illustrated in Figure 6 are operated by a handle. The handle is made from a short length of steel tUbing pair of notches at one end. This end is used to open and close at the base of the jack.

To lift a load with the hydraulic jack, close the valve on the jack, insert the handle into the pump and move the handle up and down. The pump handle need not move through a full stroke in order to raise the load; however, the shorter the stroke of the handle, the smaller the movement of the lifting piston. To lower loads supported by a hydraulic jack turn the valve at the base of the jack counterclockwise. The speed at which the load is lowered is directly proportional to the amount the valve is opened. You should open the valve slowly to avoid lowering the load too quickly.

I
." ~

Hydraul ic jacks ay'e geneY'ally consi dered safeY' than mechani cal jacks, because if the hydraulic jack is overloaded to the point of causing a lift failure, the object being lifted will be lowered slowly. When mechanical jacks suffer a failuY'e, the load is dropped suddenly and violently.

[IJ
Floor jacks

Do not rely on a hydraulic jack remaining for a long period in a loaded position as a small leakage of fluid often takes place, gradually lowering the load.

Figures 7 and 8 illustrate hydraulic floor jacks used mainly for lifting vehicles. They must be used on hard, level surfaces such as the concrete floor in a shop. Floor jacks are designed to roll under a vehicle and to raise that vehicle without the mechanic having to reach underneath. This feature makes them safer to use than other jacks.

Floor jacks are capable of relatively high lifts. The floor jacks shown in Figures 7 and 8 can reach up to 2'-0 (600 mm) above the floor with their lifting plates.
11

The long handle on a hydY'aul floor jack has a number of uses. You can ic push, pull or steer the jack into position with the handle. If you turn the handle on a floor jack, you open and close the valve. When you pump the handle while the valve is closed, you raise the load. If the valve is open, you lower the load.

Hydraulic bumper jacks as shown in Figure 9 are used in the automotive industry, usually to raise vehicles for tire changes. They are designed to lift a vehicle by its bumper. Most bumper jacks are capable of lifting approximately 3 -0" (900 mm); however, some models are able to reach as high as 4 -6" (1350 mm).
1 1

Bumper jacks range in capacity from 1 1/2 tons (1360 kg) to 2 1/2 tons (2260 kg). Most bumper jacks are equipped with a mechanical safety lock mechanism that prevents the vehicle from being lowered accidentally. There are two basic types of hydraulic bumper jacks: those with a manually operated hydraulic oil pump and those that use compressed air as a power _. source. When you use a bumper jack, position the jack with its base on a hard, level surface and its vertical column centred on the vehicle. Adjust the two bumper pads on the jack so that they engage at the vehicle's lifting points. These lifting points are identified in the owner's manual provided by the vehicle's manufacturer.

Bumper jacks equipped with mechanical safety locks should have those mechanical safety locks engaged as soon as the vehicle is raised to the desired height. While you position blocking or metal stands (described in Learning Task 2) under the vehicle, the total weight on the bumper jack must be supported by the safety locks and not by the jack's lifting mechanism. There are many other specialty jacks found in industry, each designed for a particular purpose. All jacks, when used properly, will make your work easier and safer.

I~I
J

Now complete Self Test 1 and check your answers.

Self Test 1
Choose the best answer offered for the following questions.
1.

The size of a jack is designated by its a. b. c. d. weight length length of lift capaci ty

2.

The main floor of a house is sometimes supported by a screw jack known as a/an a. b. c. d. beam jack floor jack adjustable post basement post

3.

The mechanical advantage increases as you extend the a. b. c. d. bumper jack hydraulic jack sci ssor jack screw jack

4.

When a hydraulic jack suffers a failure, the load it is supporting will a. b. c. d. remain stationary be lowered slowly drop in short steps drop violently

5.

The lifting plate on some floor jacks can be raised above the floor up to
a.

b. c. d.

8" (200 mm) 11-0" (300 mm) 2'-0" (600 mm) 41-0" (1200 mm)

6. The safety lock mechanism on a bumper jack is used to prevent the a. b. c. d. bumper from slipping off the jack accidental lowering of the jack jack from being overloaded jack from being raised too high

7. Which jack uses compressed air as a power source? a. b. c. d. scissor jack floor jack bumper jack lever jack

8. To use a screw jack in a confined area you are required to a. b. c. d. use a shorter handle relocate the handle after each short turn use a ratchet handle use a bent handle

.,

9. A crank handle is used to operate a. b. c. d. hydraulic jacks floor jacks scissor jacks bumper jacks

10. To lower a load supported by a hydraulic jack you must a. b. c. d. flip the lever downward set the pump to reverse lift the handle as high as possible open the valve

Learning Task 2: Describe safe procedures for using jacks

One of the first and most important rules to consider when using any kind of jack is that the load must not exceed the capacity of the jack.

[I]

Jacks are not intended to act as supports for extended periods of time. If a load is to remain raised for an extended period of time, you must provide support for the load other than the jack. This additional support is also required when personnel must work under the raised load.

Two basic types of supports are commonly used: manufactured metal stands as illustrated in Figure 1 or solid wood blocking as shown in Figure 2.

Manufactured metal stands are available in a variety of capacities from 1 ton to 10 tons each. When you use metal stands, remember that: . the load must not exceed the capacity of the stands and . the metal stands must be on a concrete floor'. Metal stands are equipped with relatively small feet that sink into any surface softer than concrete. If you use a number' of metal stands to support a load on hard-packed soil, gravel or even asphalt paving, you risk having the load topple because the stands will sink into the ground at different rates.

Wood blocking as illustrated in Figure 2 distributes the weight of a load over a larger area than a jack does so that using wood blocking helps prevent the load from sinking. The base area of wood blocking should be increased when blocking is used on soft ground. Wood blocking is built up by laying each tier, or row, at right angles to the previous tier. Each tier should be level before you proceed with the next tier. Because the placement of wood blocking varies with the type of load it supports, your instructor will demonstrate some blocking arrangements for you before you begin the Practical Competency at the end of this learning guide. The portion of a load that rests on supports must not be allowed to slide off the supports. If the equipment being supported is machinery that rests on wheels, the safest way to prevent the wheels from accidentally rolling is to block them with chocks. Any item being raised or lowered by jacks must be prevented from moving horizontally as such movement will cause the supports to tip over.

General safety requirements

2.

You must not use jacks to support loads for extended periods of time or while personnel work under the load. Use blocking or manufactured metal stands. Always ensure that the jack is plumb during a lift. Any leaning of the jack causes a horizontal force to the load and could cause the load to shift sideways. Make sure flat tops and other when they the load cannot slip off the top of the jack. Jacks with should lift only against flat, level surfaces. Vehicle axles cylindrical shapes should be cradled in concave jack-tops are being lifted.

3.

4.

6. 7.

Always use manufactured load.

metal stands or wood blocking to support the

Always use wheel chocks to prevent vehicles from moving during jacking.

I~'NOW

complete Self rest 2 and check your answers.

Choose the best answer for the following questions. 1. Personnel may work under a load that is supported by a. b. c. d. a hydraulic jack a mechanical jack blocking a bumper jack

a. b. c. d. 3.

placed on end less than 2 -0" (600 mm) high made of hardwood cross-stacked at each tier
1

If you are using wood blocking on soft ground you must increase the a. b. c. d. height of base area number of length of the blocking of the blocking tiers the jack

a. b. c. d.

fastened to the previous tier smaller than the tier below made of hardwood level

a. b. c. d.

a bumper jack with safety locks blocki ng or metal stands hydraulic jacks two or more jacks

6.

If you are using a jack to raise one end of a wheeled vehicle, the safest way to prevent the vehicle from moving is to use a. b. c. d. wheel chocks the emergency brake the parking gear blocking or metal stands

Learning Task 3: Describe the care and maintenance of jacks

Jacks are designed to provide years of trouble-free service if they are given proper care and maintenance.

Care of jacks Before using any jack you should inspect it by looking for signs of: wear stress insufficient lubrication

Wear usually shows up as a shiny or worn surface. Wear is detected both by sight and by feel. Badly worn parts should be replaced. To prevent further wear, moving parts should be lubricated.

~\ ,.,

Stress is detected visually. Stress on a jack or metal stand is indicated by cracked welds, cracked paint, freshly flaked away rust, bent parts, or misaligned parts. Cracked welds can be repaired by a competent welder but bent pieces should be replaced.

If a jack squeaks or requires more force than usual to operate, it has probably not been adequately lubricated. Apply either oil or grease at all locations indicated by the jack manufacturer's lubrication guide. The screw threads on screw jacks, scissor jacks, and on the top end of hydraulic jacks are often overlooked for lubrication. The screw threads should be brushed with a wire brush or washed in solvent to remove all dirt and dried lubricants. Then the threads should be lubricated with a heavy oil and the screw turned through its full length to ensure that the oil coats the entire screw.

J
Maintenance of jacks On each type of jack certain areas must be checked to see if maintenance is required. You should refer to the maintenance guide supplied by the jack's manufacturer. Some general guidelines for maintenance of jacks follow.

As mentioned earlier, the screw thread must be kept clean and well lubricated. In addition, the surfaces between the top of the screw and the head of the jack must be lubricated.

The screw and all pivot points of a scissor jack must be cleaned and lubricated. You should check for signs of wear at all joints and replace any jacks that show signs of excessive wear or that have bent or cracked parts.

Lever jacks have many moving parts that all must be kept clean and well lubricated. Check all parts for signs of stress and discard any jacks showing cracked or bent parts. Be sure to inspect the teeth or notches for signs of wear. Discard the jack if either the notches or the dogs which engage the notches show excessive signs of wear .

Hydraulic jacks

Hydraulic jacks should be checked for signs of leaks. There are three places on a hydraulic jack where leaks may occur: the area where the lifting piston comes out of the jack, the top of the pump, and the area around the valve. Excessive oil showing near these areas indicates a leak. Leaks can be repaired by dismant~ the jack and replacing the seals. Another type of leak in a hydraulic jack shows up when the jack will not support a load. If you have closed the valve tightly yet the jack allows the load to slowly lower, the valve has an internal leak which is allowing the fluid to flow back to the reservoir. To remedy this problem you must replace the defective valve components.

If a hydraulic jack does not extend its lifting piston fully, it is an indication that the jack is low on fluid. You should refill the reservoir in the jack with the recommended grade of hydraulic fluid to permit full extension of the jack. Floor jacks All moving parts should be checked for wear, stress and adequate lubrication. You should check and service the hydraulic system as you would for any hydraul ic jack. Bumper jacks The trolley mechanism which runs up and down the vertical stem should be checked for signs of stress. The small steel wheels should turn freely as the trolley moves along the stem. The horizontal beams which support the two lifting pads should be checked for signs of stress. The lifting pads should slide freely along the beams The two lifting pads should be checked to see that they cradle the bumper and prevent the bumper from sliding off the jack. If the jack has safety locks, check them to make sure they cannot be released while the jack is supporting a load. Replace safety locks that show signs of wear.

I I

Jacks should be stored in dry locations. If they must be exposed to moisture they should be wiped with an oily cloth to keep them from rusting. Hydraulic jacks should not be exposed to excessive heat for long periods of time as the rubber seals will harden and begin to leak. You shoul d always use only the handl e~ igned for the jack. Longer handles may offer too much leverage and so place too much strain on the jack. Handles that do not fit the handle receptacle tightly will eventually deform the receptacle.

"

I~'

Store jacks out of harm's way. If a jack is run over by a vehicle or if a heavy object is dropped on the jack, you risk cracking or breaking any cast metal parts or bending malleable iron parts. Such damage could make a jack unsafe to use.

Now complete Self Test 3 and check your answers .


1. Cracked paint or freshly flaked rust on a jack could be a sign of a. b. c. d. 2. improper storage lack of lubrication wear stress Exposing a hydraulic jack to excessive heat may cause damage to the a. b. c. d. 3. hydrau1ic flu id seals malleable iron parts pistons

If a hydraulic jack cannot be fully extended it indicates that it needs a. b. c. d. hydraulic fluid lubricating new seals a new valve

4.

If a hydraulic valve has an internal leak the jack will a. b. c. d. lose a11 its f1uid not extend fully slowly lower its load when the valve is closed require heavier hydraulic fluid

5.

To ensure that the screw threads on a screw jack are completely coated with oil, you apply oil to the threads and then a. b. c. d. wipe the thread with a rag brush the threads turn the screw through its full length apply oil to the nut


7. 8.

Bent components a. b. c. d. Screw a. b. c. d. heat stress wear lubrication threads

on a jack are usually

the result

of excessive

on a jack should be lubricated

and

checked for cracks replaced often cleaned filed to remove burrs pads on a bumper jack must

The two lifting a. b. c. d.

protect the finish of the bumper extend to the full width of the bumper firmly clamp to the bumper prevent the bumper from sliding off the jack

Answers

f.,
1~IThen

are on page 135.

Now complete the Written Competency H-4. "Use jacks".

proceed to the Practical Competency on page 136.

Answer Sheet
Self Test 1 1. d. 2. c. pages 122-123

.:
I
1
I I

I
j
I

capaci ty adjustable post

tl

:)
d

11
it

:\

4.
5.

b.
c.

be lowered slowly
21-0" (600 mm)

6.

b.

accidental lowering of the jack bumper jack relocate the handle after each short turn

7. c. 8. b.

Self Test 2 1. 2. 3.

pages 126-127

c. d. b.

blocking cross-stacked at each tier base area of the blocking

1eve 1

4. d. 5. b.
6. a.

blocking or metal stands wheel chocks

Self Test 3 1. 2. 3. 4. 5. 6. 7. 8. d. b. a. c. c. b. c. d.

pages 132-133

stress seals hydraulic fluid slowly lower its load when the valve is closed turn the screw through its full length stress cleaned prevent the bumper from sliding off the jack

Practical Competency 1: Use jacks

various types of jacks . manufactured metal stands

assortment of wood blocking wheel chocks

I
\

I
Contact your instructor to make arrangements to complete this practical competency. Your instructor will introduce you to a selection of jacks commonly used in your trade. You will be instructed on the jacking projects you must complete for this Practical Compe~ency. Your instructor will indicate the: items to be raised and lowered, 2. 3. jacks to use, type of blocking to use (wood or metal stands), height to raise each item, placement of the jacks, and placement of blocking. I

--

Read those checklists which relate to the jacks you will be using so that you can identify how your skills will be evaluated. When using jacks remember to: check that the jack has adequate capacity for the lifting operation, check the jack for defects, adjust the jack to its lowest position,
~/

 set the jack on a level, firm base which raises the jack as high as is practical, secure the load to prevent any horizontal movement, ensure that the jack is exactly vertical during the lift to prevent the load from moving horizontally, use blocking to support the load at the desired height, and always position yourself out of harm's way in case the load drops. 4. Use jacks to raise and lower the loads selected by your instructor.

I~ I

5.

Ask your instructor to evaluate your performance.

Checklist: Use jacks

A. Use screw jacks

DATE: ATTEMPT: 1 2 3 4

STUDENT'S NAME STUDENT'S 1.D. # Each item is worth 10 points. Mark:

3. Adjusted jack to lowest position. 4. Placed jack on an adequate base. 5. Blocked jack as close to load as practical.

8.

Raised load to specified height.

9. Correctly supported load with blocking or metal stands. 10. Lowered load to its original position. *11. *12. Returned all tools to storage. Observed all shop safety rules.

*These items must be completed with 100% accuracy. Comments:

Checklist: Use jacks

B. Use lever jacks

STUDENT'S NAME STUDENT' S 1.0. # Each item is worth 10 points. Mark:

DATE: ATTEMPT:
1 2

3 4

3. Adjusted jack to lowest position. 4. Placed jack on an adequate base.

5. Blocked jack as close to load as practical.

8. 9.

Raised load to specified height. Correctly supported load with blocking or metal stands.

10. Lowered load to its original position.

*11. *12.

Returned all tools to storage. Observed all shop safety rules.

Instructor's Signature

--------------

Checklist: Use jacks

C. Use scissor jacks

DATE: ATTEMPT: 1 2 3 4

STUDENT'S NAME STUDENT'S 1.D. # Each item is worth 10 points. Mark:

\
\

3. Adjusted jack to lowest position. 4. Placed jack on an adequate base. 5. Blocked jack as close to load as practical.

.i
I.

I
I

I
\

*7. Positioned jack vertically for lift. 8. Raised load to specified height. 9. Correctly supported load with blocking or metal stands. 10. Lowered load to its original position. *11. *12. Returned all tools to storage. Observed all shop safety rules.

Checklist: Use jacks

D. Use hydraulic jacks

STUDENT'S NAME STUDENT1S 1.0. # Each item is worth 10 points. Mark:

DATE: ATTEMPT:
1 2

3 4

1. Inspected jack for defects. 2. 3. 4. 5. Notified instructor of any defects. Adjusted jack to lowest position. Placed jack on an adequate base. Blocked jack as close to load as practical.

8. 9.
10.

Raised load to specified height. Correctly supported load with blocking or metal stands. Lowered load to its original position. Returned all tools to storage. Observed all shop safety rules.

*11. *12.

Instructor's Signature

--------------

Checklist: Use jacks

E. Use floor jacks

STUDENT'S NAME STUDENT'S 1.D. #

DATE: ATTEMPT: 1 2 3 4

1. 2. 3.

Inspected jack for defects. Notified instructor of any defects. Adjusted jack to lowest position.

5. 6. 7. *8. *9.

Raised load to specified height. Correctly supported load with blocking or metal stands. Lowered load to its original position. Returned all tools to storage. Observed all shop safety rules.

Instructor's Signature

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H-4 PRACTICAL COMPETENCY 1

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Checklist: Use jacks

F. Use bumper jacks

STUDENT'S NAME STUDENT'S 1.D. # Each item is worth 10 points. Mark:

DATE: ATTEMPT: 1 2 3 4

1. 2. 3. *4.

Inspected jack for defects. Notified instructor of any defects. Adjusted jack to lowest position. Centered jack's vertical column to load.

5. Adjusted lifting pads to coincide with bumper's attachment points. *6. 7. 8. 9. 10. *11. *12. Correctly used wheel chocks. Raised vehicle to specified height. Engaged safety locks on jack. Correctly supported vehicle with blocking or metal stands. Lowered vehicle to ground. Returned all tools to storage. Observed all shop safety rules.

Instructor's Signature

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