CORPORATE SAFETY MANUAL

Transcription

1 CORPORATE SAFETY MANUAL Procedure No Revision: Date: May 2005 Total Pages: 10 PURPOSE To provide general guidelines for the inspection of all ropes, chains, cables, slings, etc. used for personnel and material handling prior to use and as deemed necessary during their use, in order to ensure the safety of our workers. SCOPE This section applies to all Riley Construction Company, Inc. operations. POLICY Although OSHA Standard 29 CFR pertains primarily to rigging equipment for material handling, the rope, cable and sling portions of this section will be applied to all hoisting equipment, winches, and safety lines in use by Riley. The OSHA guidelines regarding visual and detailed inspections, disposition of damaged items, and lubrication procedures, will be the policy of this organization. NOTE: OSHA guidelines for materials handling, storage, use, and disposal, are also covered within section 29 CFR COMPETENT PERSON The use of ropes, cables, chains, slings, etc. regardless of whether they are made of natural or synthetic fibers, steel wire, or metal mesh, are subject to certain hazards that cannot be met by mechanical means, but only by the exercise of intelligence, care, and common sense. It is therefore essential to have personnel involved in the proper care, use and inspection of this equipment who are competent, careful and well trained. VISUAL INSPECTION Since safety depends on the proper operation of all types of ropes, cables, chains, slings, etc. a visual inspection of these items must be performed daily by an appointed person. Items to look for while conducting the visual inspection should include the following: Kinks or severe twists Cracks Nicks, breaks, frayed or unraveled edges Deformed, worn or flattened surfaces

2 Corroded or pitted surfaces Shortened or lengthened rope lays DETAILED INSPECTION The following, more detailed inspection, may be performed by a competent person at least daily, or at more frequent intervals, depending on operating conditions and use: Run out rope completely and note conditions, such as number of broken strands, broken wires in one lay, reduction in rope diameter, corrosion, shorting of the lay, or fraying. Run a soft cloth, preferably cotton, over the entire length of wire rope and examine any rope lays that pick up threads of the cloth. Determine the extent of damage due to broken wires, nicks, cuts, frayed or unraveled edges. Ensure that wire rope is properly lubricated. When any of the above conditions exist and show evidence of abnormal deterioration, the item must be watched and re-inspected daily. If this condition continues to worsen, the item must be condemned and replaced. DISPOSITION OF DAMAGED ROPE NOTE: Any rope, cable, chain, sling, etc. removed from service due to a damaged condition must be destroyed immediately. The length and type of service, as well as the severity of operation, must be taken into consideration before determining the disposition of ropes or cables that show signs of damage. Where failure of the rope, cable, chain, sling, etc. might endanger life or equipment, the rope, cable, chain, sling, etc. must be condemned and replaced immediately. In all cases, the rope, cable, chain, sling, etc. must be condemned and replaced if any of the following conditions are found to exist. Broken Wires: Six or more wires broken in any one wire lay, or three or more wires broken in any one strand of one rope lay. Worn Outside Wires: Wearing of one-third or more of the original diameter of any of the outside individual wires. Broken Strand: One or more broken strands.

3 Kinking, Crushing, Un-stranding, or Other damage: Rope which is severely kinked, crushed, cut, frayed, bird caged, un-stranded, or unraveled, or any other damage resulting in distortion of the rope structure. Heat or Weld Damage: Any evidence of heat damage or weld splatters. Corrosion: Considerable corrosion in the valleys between strands or corroded or broken wires at end connections. Reduction in Diameter: Noticeable reduction from normal rope diameter. Chains: Cracks, elongation, rust, etc. Nylon and/or Synthetic straps: Cracks, welding burns, fraying, when the indicator cords are showing, etc. ROPE CLIPS Fixtures are usually attached to wire rope by means of wire rope clips, commonly referred to as either "U" clips or "U" bolts. These wire rope clips are also used when making a loop at the end of a wire rope. There is a right way and a wrong way to use a wire rope clip. The correct method for installing a wire rope clip is to attach the clip with the base or saddle of the clip against the live, or long end of the rope, and the rounded "U" portion of the bolt over the short or dead end of the wire rope. This will allow the clip to develop 80 to 90 percent efficiency and is the only correct method of attaching wire rope clips. The saying, "Never Saddle a Dead Horse" will help prevent incorrect mounting of wire rope clips.

4 CLIPS WARNINGS AND APPLICATION INSTRUCTION G-450 (Red-U-Bolt) SS-450 Stainless Steel) WARNING Failure to read, understand, and follow these instructions may cause death or serious injury. Read and understand these instructions before using clips. Match the same size clip to the same size wire rope. Prepare wire rope end termination only as instructed. Do not use with plastic coated wire rope. Apply first load to test the assembly. This load should be of equal or greater weight than loads expected in use. Next, check and retighten nuts to recommended torque (SEE TABLE-1). Efficiency ratings for wire rope end terminations are based upon the catalog breaking strength of wire rope. The efficiency rating of a properly prepared loop or thimble-eye termination for clip sizes 1/8" through 7/8" is 80%, and for sizes 1" through 3-1/2" is 90%. The number of clips shown (SEE TABLE-1) is based upon using RRL or RLL wire rope, 6 x 19 or 6 x 37 Class, FC or IWRC; IPS or XIP. If Seale construction or similar large outer wire type construction in the 6 x 19 Class is to be used for sizes 1 inch and larger, add one additional clip. If a pulley (sheave) is used for turning back the wire rope, add one additional clip. The number of clips shown also applies to rotation - resistant RRL wire rope, 8 x 19 Class, IPS, XIP, sizes 1-1/2 inch and smaller; and to rotation-resistant RRL wire rope, 19 x 7 Class, IPS, XIP, sizes 1-3/4 inch and smaller. For other classes of wire rope not mentioned above, we recommend contacting Crosby Engineering at the address or telephone number listed at the end of the catalog to ensure the desired efficiency rating. For elevator, personnel hoist, and scaffold applications, refer to ANSI Al 7.1 and ANSI Al 0.4. These standards do not recommend U-Bolt style wire rope clip terminations. The style wire rope termination used for any application is the obligation of the user.

5 For OSHA (Construction) applications, see OSHA REFER TO TABLE-1 in following these instructions. Turn back specified amount of rope from thimble or loop. Apply first clip one base width from dead end of rope. Apply U-Bolt over dead end of wire rope - live end rests in saddle (Never saddle a dead horse!). Tighten nuts evenly, alternate from one nut to the other until reaching the recommended torque. 2. When two clips are required, apply the second clip as near the loop or thimble as possible. Tighten nuts evenly, alternating until reaching the recommended torque. When more than two clips are required, apply the second clip as near the loop or thimble as possible, turn nuts on second clip firmly, but do not tighten. Proceed to Step When three or more clips are required, space additional clips equally between first two - take up rope slack - tighten nuts on each U-Bolt evenly, alternating from one nut to the other until reaching recommended torque. 4. WIRE ROPE SPLICING PROCEDURES: The preferred method of splicing two wire ropes together is to use interlocking turnback eyes with thimbles, using the recommended number of clips on each eye (See Figure 1). An alternate method is to use twice the number of clips as used for a turnback termination. The rope ends are placed parallel to each other, overlapping by twice the turnback amount shown in the application instructions. The minimum number of clips should be installed on each dead end (See Figure 2). Spacing, installation torque, and other instructions still apply. Figure 1 Figure 2

6 5. IMPORTANT Apply first load to test the assembly. This load should be of equal or greater weight than loads expected in use. Next, check and retighten nuts to recommended torque. In accordance with good rigging and maintenance practices, the wire rope end termination should be inspected periodically for wear, abuse, and general adequacy. Table 1 Clip Size (Inches) Rope Size (Inches) Minimum No. of Clips Amount of Rope to Turn Back in Inches * Torque in Ft. Lbs. 1/8 1/ / /16 3/ / /4 1/ /4 15 5/16 5/ /4 30 3/8 3/ /2 45 7/16 7/ /2 1/ /2 65 9/16 9/ /8 5/ /4 3/ /8 7/ /8 1-1/ /4 1-1/ /8 1-3/ /2 1-1/ /8 1-5/ /4 1-3/ /4 2-1/ /2 2-1/ /4 2-3/ /2 3-1/ If a pulley (sheave) is used for turning back the wire rope, add one additional clip. If a greater number of clips are used than shown in the table, the amount of turnback should be increased proportionately. * The tightening torque values shown are based upon the threads being clean, dry, and free of lubrication.

7 Forged Wire Rope Clips CLIPS Rope Size Std Package Qty. Weight Per 100 (lbs.) Dimensions A B C D E F G H * 1/ * 3/ / / / / / / / / / / / / / /8 Bulk /4 Bulk Bulk /4 Bulk /2 Bulk /4 Bulk Bulk /2 Bulk * Electro-plated U-Bolt and Nuts 2 3/4" and 3 1/2" base is made of cast steel Each base has a Product Identification Code (PIC) for material traceability, should be forged into it. Sizes 1/8" through 2 1/2" have forged bases. Entire Clip - Galvanized to resist corrosive and rusting action. Only Genuine Crosby Clips have a Red U-BOLT for instant recognition. All Clips are individually bagged or tagged with proper application instructions and warning information. Clip sizes up through 1 1/2" have rolled threads. Crosby Clips, all sizes 1/4" and larger, meet the performance requirements of Federal Specifications FF-C-450 TYPE 1 CLASS 1, except for those provisions required of the contractor.

8 THE SS-450 "316" STAINLESS STEEL WIRE ROPE CLIPS SS-450 Rope Size SS-450 Stock No. Weight Per 100 Dimensions (lbs.) A B C D E F G H 1/ / ¼ / ½ / Each base has a Product Identification Code (PIC) for material traceability, the name CROSBY or "CG", and a size forged into it. Available in sizes 1/8 through 5/8". Entire clip is made from 316 Stainless Steel to resist corrosive and rusting action. All components are Electro-Polished. All Clips are individually bagged or tagged with proper application instructions and warning information.

9 Fractional Decimal and Metric Conversion Table Decimal Metric (mm) Decimal and Metric Conversion Table Fractional Decimal Metric (mm) 1/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / ¼ / / / / / / / / / / / / / / / / / / / / / / / / / / / /32 31/ /32 63/ ½ MASS CONVERSIONS TO CONVERT FROM U.S. TONS TO METRIC TONS MULTIPLY BY TO CONVERT FROM METRIC TONS TO U.S. TONS MULTIPLY BY TO CONVERT FROM METRIC TONS TO POUNDS MULTIPLY BY TO CONVERT METRIC TONS TO KILOGRAMS MULTIPLY BY 1000 TO CONVERT FROM POUNDS TO KILOGRAMS MULTIPLY BY TO CONVERT FROM KILOGRAMS TO POUNDS MULTIPLY BY TEMPERATURE CONVERSION TO CONVERT FROM DEGREE FAHRENHEIT TO DEGREE CELSIUS USE Tc=5/9(Tf-32) TO CONVERT FROM DEGREE CELSIUS TO DEGREE FAHRENHEIT USE Tf=9/5(Tc)+32

10 SLINGS NOTE: Any sling removed from service due to a damaged condition, must be destroyed immediately. Slings are generally used in conjunction with other material handling equipment for the movement of material by hoisting. Slings are made of alloy steel chain, wire rope, metal mesh, natural or synthetic fiber, or fibers woven into a web. Many manufacturers of slings will produce their slings with a safety mark already on them. An example of this would be a sling with a red colored strand woven right into the material. If the sling has been cut or nicked to the point where the red colored strand is visible, the sling should be replaced immediately. However, since not all manufacturers make this safety mark, it will be up to the inspector to determine when the sling should be replaced. SLING INSPECTION Each day, before being used, the sling and all fastenings and attachments must be inspected for damage or defects by a competent person designated by the Company. Additional inspections should be performed during sling use, and where service conditions warrant. Damaged or defective slings must be immediately removed from service and destroyed. In the case of alloy steel chain slings, the inspection shall include a thorough check for wear, defective welds, deformation of the links, and increase in length. Where such defects or deterioration are present, the chain sling must be immediately removed from use.