Heavy load rigging operations are a part and parcel of every industry. Rigging operation include, hoisting/lifting of heavy loads, pushing or pulling of loads, and demolition operations. These operations can prove hazardous if not handled safely. The best way to conduct safe rigging operations is to ensure safe use of rigging equipment and also carrying out proper inspection and testing of the rigging hardware.
It is imperative that these pieces of equipment should be tested and examined properly by a competent examiner at the time of rigging. The rigging equipment should be fixed to safe anchor points to ensure proper function and the safety of the users.
The following notes will allow you to take proper measures for making your rigging operations safer:
1. Inspection
The safety and reliability of any rigging hardware cannot be ensured unless it has received proper inspection.
Regular inspections are particularly important because they provide a useful means of detecting potential hazards which contribute to accidents. Regular inspections also forewarn the owner to conduct necessary preventive maintenance or repair of the damaged gear.
The purpose of such inspection is to find out whether there is any abnormal wear or tear, oil leakage, abrasion, corrosion, visual cracking, malfunction, misalignment, overloading, excessive vibration, abnormal slackening, unusual sound, dislocation etc. In case of any such damage subsequent remedial actions such as repair, replacement or withdrawal of the defective parts should be undertaken immediately.
A weekly inspection should be covered as broadly as possible. They should include the inspection of all possible mechanisms as widely as possible.
The hoisting mechanisms such as wire ropes, pulleys, slings and the various end fastening's should be checked properly. The functional mechanisms such as sheaves, brakes, and locking mechanisms such as hooks, limit switches, control switches, and buttons should be examined as well. The fixing and anchoring hardware is of equal importance and should also be inspected thoroughly.
Daily inspections should be carried out before and after every rigging operation to ensure that the equipment are functioning properly. All equipment that has a direct bearing to the safety of the operation should be inspected on a regular basis. For example, the control mechanism, control switches, levers, hydraulic hoses, oil level of hydraulic and fuel systems must be examined thoroughly by the user before every use.
The lack of such inspection can cause serious deterioration of the lifting appliance and an expensive replacement or repair charge.
2. Examination
A thorough examination should cover those rigging hardware that are subjected to certain type of wear and tear, deterioration or malfunction. This includes Visual examination, Dimensional, Functional examination, electrical test and examination, open-up examination, and non-destructive examinations.
A visual examination should cover the inspection of all individual rigging hardware in use. It includes testing and inspection of lifting gears such as ropes, slings and pulleys, connecting hardware like hooks, blocks, clamps, and joint and mast and jib configurations.
A dimensional examination will include measurement of linear dimensions such as diameter, thickness, clearance of a component, the diameter of the wire rope, etc.; it also includes the span limit and alignment of the load to verify the stability of the load bearing equipment used. And ensuring the limit of the load limit switches is a part of this inspection.
The functional examination mainly includes the no-load test. It is important to take proper measures so that one does not exceed the load limit. A non-load test checks the lifting and booming mechanisms, brake operations, swinging and slewing as well as the traveling mechanisms. The functioning of alarm switches, load-limit, safety devices and indication lamps should be checked.
The opening up examination includes the examination of concealed or covered gears. For example, gearboxes in the drive train, brake linings or brake discs of the braking system should be checked for any damages.
The electrical examination should be carried out by registered electrical workers. This test includes examinations such as ensuring proper earthing and protection from electrical circuits. The connection of the electrical appliance to the source should be safe and proper. The electrical cables and wire should be checked for damage or cuts regularly to ensure safety.
The examiner or the user should select the best type of examination that may assist him to determine the safe working condition of that gear, depending on the type, model and working capacity of the rigging gear.
3. Testing
Once the rigging hardware has undergone appropriate inspection and examinations, it should then be subjected to proper testing to ensure safety. Testing generally includes proof load test, wherein the maximum capacity of the gear is calculated.
Proof load testing includes performing test loading operations prior to the actual loading to make sure that the equipment can bear the load capacity. It is important to select the appropriate type and amount of proof load based on the various relevant national/international safety standards, codes of practice or the manufacturer's specifications mentioned on the gear itself.
The test weights should be kept as close to the ground as possible. Safety should be ensured if the testing operation involves, lifting or traveling along with the load. Adequate precaution should be taken while testing that the load doesn’t swing or rotate while lifting.
It is important to confirm the configuration of the rigging equipment and also perform proper adjustments to align the load appropriately so that it does not slip off the rigging gears.
End words
The user should ensure a safe system of work which includes regular examination, test and inspection of all rigging hardware. A safe working environment will increase productivity, efficiency and profit margins.
Proper examinations, testing and inspection of the rigging equipment will allow the user to detect any damage occurred. This will further allow replacing or repairing such gears for safer use. It is always advisable to concern a competent examiner while conducting such tests for better results.