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1. ee ee ee and for MS and S Slings is 20 or greater where D Diameter of curvature around which th MS Mechanical Splice je body of the sling is bent d Diameter of rope HT Hand Tucked Splice For hidden tuck splice IWRC Table H 3 values in HT column Table 7 OSHA 1926 251 Tables H 3 to H 4 Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 27 of 108 OSHA Table H 5 and Table H 6 give the give the capacity ratings for single leg sling for construction galvanized aircraft grade rope and IWRC construction improved plow steel grade rope Three different arrangements are calculated vertical leg looped as a basket and a choker The tables give the capacities based on minimum bend radius requirements and an assumed termination of a mechanical splice S Swaged or Zinc Poured Socket TABLE H 5 RATED CAPACITIES FOR SINGLE TABLE H 5 RATED CAPACITIES FOR SINGLE LEG SLINGS LEG SLINGS Continued Cable Laid Rope Mechanical Splice Only Cable Laid Rope Mechanical Splice Only 7x77 and 7x7x19 x Galvanized Aircraft Grade 7x77 and 7x7x19 Galvanized Aircraft Grade ope ope 7Tx6x19 IWRC Construction Improved Plow Steel Grade Rope 76x19 IWRC Construction improved Plow Steel Grade Rope TTT 27x66x19 ki TTT 22 27x619 TTT 37 2 a DT 55 Meme M 7x7xT 76 gt 26 49 Se 7x7xi9 58 a Ms 7x719 8
2. ES pa a g a amp 85 SlingLength 6 2xL L D 0 57 Difference of Sling Length 10 00 7 50 5 00 2 50 0 00 2 50 5 00 7 50 10 00 45 DB 3 75xL 50 DB 2 5xL DB 1 25xL L D 0 57 amp a L 24 a o Ci 85 Figure 11 Comparison of Load Share for Various Aspect Ratio Equalizer Plates Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 78 of 108 Flounders and Equalizers in Complex Rigging Arrangements Large lifts of typical ship structure often requires the distribution of the sling forces to a large area such as to eliminate concentrated loading that can be detrimental both local structure and the global response of the entire block Some very flexible small assemblies also require a complex system of spreader beams flounder plates and equalizers because they are not capable of supporting themselves from a minimal number of lifting points without excessive deflection or distortion A typical example of a two crane four equalizer plate complex rigging arrangement commonly used to distribute loading can be seen in Figure 12 Figure 12 Two Crane Eight Sling Spread Rigging Arrangement In this figure we see each crane holding a spreader bar with two equalizer plates underneath and a total of eight slings attached to the block Although the load for each crane can be calculated wi
3. fi h z30 36 40 Figure 29 Adjustable Box Bar Spreader Beam Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 95 of 108 Round Spreader Beam Round bar has a lift capability of 210 tons and span of 14 ft with effectively two padeyes on top and two on bottom located on each end This spreader is similar to the adjustable box beam spreader for use but cannot be adjusted with regards to spread distance Figure 30 Round Bar Spreader Beam Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 96 of 108 Telescoping Spreader Beam Other spreader bars in existence include modular and telescoping spreader bars These have the advantage of relatively easily breaking down or reducing in size such that can be transported or stored easily An example of a telescopic bar can be seen in Figure 31Figure 31 Telescoping Spreader Beam which has a 50 ton lifting capability up to 65 ft in length with 6 in adjustment increments With significant adjustment possible vertical slings can be used minimizing internal moments and compressive forces will be imparted into the ships block during the lift These spreader beams typically cannot be used as an equalizer because they are not designed for internal moment 93 00 PIN AND LANYAR
4. 5 FLOUNDER PLATES AND EQUALIZERS Load Sharing Rigging Device Overview Large blocks of ship structure lifted during construction often need to be picked up from multiple locations This is due to the desire to spread the rigging forces over a larger area to avoid concentrating the loads imposed in just a few locations This is often achieved through the use of rigging devices such as spreader bars equalizer beams and flounder plates to transfer the loads from one sling to two or more The main geometric distinction between these devices is that flounder plates are smaller with an aspect ratio near unity and equalizer beams are typically much larger with higher aspect ratios The proper function of these devices is dependent on several factors such as sling length sling elasticity block flexibility aspect ratio of the flounder or equalizer plate size of the flounder or equalizer plate and other geometric relations of a given arrangement Figure 1 Load Sharing Device Near the End of Spreader Beam Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 68 of 108 As flounder plates and equalizers beams are often used in statically indeterminate arrangements a solid understanding of critical factors relating to how they share or balance the load is necessary Some of the main factors for how the load is shared is the location of the center of gravity sling le
5. Fig te 7 Typesof Wire Rope Bids sussisicenasreorir a a a 22 Figure 8 Wire Rope Efficiencies for Various D d Ratios seesseeeeseseeeierreeresrrssrreresee 24 Figure 9 Choker Hitch Bice mn yt acpi ce don astan dd ie dadtadsleadineetecesbancaee a ariei 25 Figure 10 Relationship Between Pin Size and Wire Rope Loop seeceeeeereeseererene 25 Figure 11 Statically Determinant Lift Arrangements Covered by OSHA Regulations 26 Figure 12 Component Construction of a Single Path Roundsling eee eeeeeeeeeees 36 Figure 13 Twin Path sling length and Measurement ces ceeeeeeseeeseeceeceeeeeeeeeeaeeeaeens 38 Figure 14 Approximate Elongation of New Sling vs Old with Shrunken Cover 39 Figure 15 Basket Hitch With Spread Slings for Better Load Control s es 39 Figure 16 90 Degree Twisting of Twin Path SIling eeesseseseesseerreseesersresrreresrrsseeeresee 40 Figure 17 Three Main Sling Hitches Basket Vertical and Choker eeeeeeeeeeeeeees 41 Figure 18 Comparison of Reduction Factors for Eye Sling and Endless Roundsling 42 Figure 19 Bunching of a Sling in a Shackle xc excotcscwecusecunnbaacaviend seccvapsnecetnedusenmneianctegaieaes 43 Figure 20 Cyclically Tested Twin Path Test Slings eesessesseseeerreseerersreerrerresressereresee 45 Figure 21 End Connections for Vertical Hitches esesseeeeeseeeeeserereereesrrsererresressrerresee 46 Figure 22 Cover Inner and Outer Core Fi
6. 0 Size and dimensions of components should be available for parts used such that critical dimensions can be checked against mating surfaces and overall sizes may give indications of possible interferences 0 Capacity of lift components should be available so the proper one can be selected without significant probability of failure CL Properties of components are important for they may degrade under certain conditions or have limitations based on environmental fatigue wear or other operations factors LJ End connections of items should be documented so it is known what items can be linked to other and where limitations exist Regulations and standards that affect the use of an item should be that when checking physical limitations regulatory requirements can be reviewed Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 7 of 108 1 PADEYE Design Philosophy A Padeye is type of pin connection used for connecting structure to a shackle Typically on a ships block under construction they will be welded to the hull over or onto a structurally significant part of the block This is usually a sturdy frame or bulkhead As the type strength and orientation of the structure and lift can vary substantially many different shapes and geometries of padeyes have been created D Cyrene Figure 1 Examples of Padeyes Padeyes are typically s
7. 100 000 258 000 150 000 Other grades of proof tested steel chain include Proof Col BBB Coll and Hi Test Chain These grades are not recommended for overhead lifting and therefore are not covered by this code 1 Rating of multileg slings adjusted for angle of loading measured as the included angle between the inclined leg and the vertical 2 Rating of multileg slings adjusted for angle of loading between the inclined leg and the horizontal plane of the load Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 64 of 108 1926 251 29 CFR Ch XVII 7 1 03 Edition TABLE H 2 MAXIMUM ALLOWABLE WEAR AT TABLE H 2 MaxIMUM ALLOWABLE WEAR AT ANY POINT OF LINK ANY POINT OF LinkK Continued Maximum allowable Chain size inches wear inch Chain size inches Table 15 1926 251 OSHA 1926 251 Table H 1 and H 2 Chain Slings Maximum allowable wear inch Additional references for regulations and standards which cover chain are OSHA 1910 184 for Slings and ASME B30 9 Slings Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 65 of 108 4 CHAIN FALLS AND AIR HOISTS Chain falls and air hoist offer infinite precision with regards to adjusting the length of a sling and therefore the load in it and the angle of the block b
8. NCCER Gainesville Florida Shapiro Howard I Jay P Lawrence K 1980 Cranes and Derricks 3d ed McGraw Hill Inc New York New York Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 106 of 108 Slingmax Technical Bulletin 3 Dec 2003 TB3 Pin size for Twin Path Extra Slings Slingmax Technical Bulletin 4 Feb 2009 TB4 Length tolerance for Twin Path Extra slings Slingmax Technical Bulletin 4 May 2010 TB4 Length tolerance for Twin Path Extra slings Slingmax Technical Bulletin 5 Feb 1994 Wire Rope news amp Sling Technology The Case for HPF slings How to lower rigging costs in the 90 s Slingmax Technical Bulletin 6 1994 TB6 TPXC Slings vs Braided polyester Slingmax Technical Bulletin 8 Sep 1996 Fiber on Fiber Abrasion testing Slingmax Technical Bulletin 9a Aug 2006 The Crosby Group Laboratory An evaluation of TPX2500 x 4 Slingmax Twin Paths Slings Slingmax Technical Bulletin 9b Oct 1997 Tension member Technology Cyclic Tension testing and Breaking Strengths of Two Slings TMT Report FR 2247 Slingmax Technical Bulletin 13 Jun 1999 TB13 Fiber Stretch K Spec vs Polyester Slingmax Technical Bulletin 14 Sep 1999 TB14 Boron exposure an Twin Path Slings Slingmax Technical Bulletin 20 Apr 2001 TB20 Test Twin Path vs Single path slings with cut strands Slingmax Technical Bulletin 21 Jul 2001 TB21 K Spec Fiber Charact
9. fi O Figure 19 Bunching of a Sling in a Shackle Figure reprinted with permission from the CROSBY GROUP Most slings break at transitions or contact points and this is not different for synthetic slings This is why special attention must be paid to the connection and bearing points of an endless roundsling Some manufacturers of Twin Path slings recommend that only wide body shackles be used with Twin Path Extra slings and that they should be polished to a fine surface finish Shackles previously subjected to large bearing pressures which commonly happens when two shackles are linked together often have indentations which can be seen on the surface and this may reduce the capacity of the attached sling It is thought that the bearing surface needs to be smooth with no abrupt hard transitions which may locally increase bearing pressures and other stress rising effects which may shorten sling life or cause failure Similarly many shackles have manufacturing rating information forged directly into the side of the shackle bow Shackles with these imprints should be avoided as they may similarly act as stress risers The concept of having a smooth bearing surface is not limited just to the steel surface of the shackle Some Twin Path manufacturers have recommended Milking the Covermax cover before all lifts The construction of the slings protective cover is bulky and baggy with excess material that can form large wrinkles on the outside o
10. reduction of strength associated with these bending restrictions has been tabulated and can be referenced below A small bend radius will also reduce the life of a wire rope as fatigue onset will be more prone to occur Wire ropes are typically bent over the sheaves in the winch and crane through shackles or wrapped under items being lifted Sometimes wire rope is bent about itself as is done during a choker lift in which the sling is terminated to itself When a wire rope is wrapped all the way around itself as shown in Figure 1 the D d ration is one Figure 8 shows that at this ratio the capacity of the wire rope is approximately half its straight pull value Different angles of choker hitches produce different bend radiuses and have different reductions of efficiency which can be referenced in Figure 9 which is in addition to the standard reduction amount for chocker lifts Reduction in efficiency of wire rope when bent over pins of various sizes EFFICIENCY 18 22 O d RATIO WEIGHTED AVERAGE OF 6x19 AND 6x36 CLASSIFICATION ROPES FIBER CORE AND IWRC REGULAR AND LANG LAY Figure 8 Wire Rope Efficiencies for Various D d Ratios Figure reprinted with permission from the WIRE ROPE TECHNICAL BOARD Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 24 of 108 Choker Hitch Capacity Adjustment Angle of Choke Rated Capacity
11. 2xL L D 5 70 Difference of Sling Length Difference of Sling Length 10 00 7 50 5 00 2 50 0 00 250 5 00 7 50 10 00 10 00 7 50 5 00 2 50 0 00 2 50 5 00 7 50 10 00 45 45 DB 3 75xL DB 3 75xL 50 DB 2 5xL DB 2 5xL DB 1 25xL DB 1 25xL 2 a Q 3 g 9 R x 79 75 89 4 85 85 Figure 10 Comparison of Load Share for High and Low Aspect Equalizer Plate of Minimal Length at Different Spread Widths Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 77 of 108 SlingLength 6 2xL L D 5 70 Difference of Sling Length 10 00 7 50 5 00 2 50 0 00 250 5 00 7 50 10 00 45 DB 3 75xL DB 2 5xL DB 1 25xL L D 5 7 g 60 oL gog Te a 65 g z 70 75 890 85 SlingLength 6 5xL L D 1 53 Difference of Sling Length 10 00 7 50 5 00 2 50 0 00 2 50 5 00 7 50 10 00 45 DB 3 9xL DB 2 6xL DB 1 3xL L D 1 53 j s Ei L 23 Fs a Gi 70 J 75 80 85 SlingLength 10 6xL L D 1 16 Difference of Sling Length 10 00 7 50 5 00 2 50 0 00 2 50 5 00 7 50 10 00 45 DB 6 4xL DB 4 3xL DB 2 1xL L D 1 16 L 14
12. 70 F control sample The extrapolation of a best fit curve of this data also shows an estimation of reduction of strength with temperature and indicates that a healthy margin of retained strength is maintained through all expected ambient temperatures that are encountered at US shipyards Although there is not complete consensus among the different manufacturers the current safe exposure temperature range as quoted by Slingmax is 40 F to 180 F This safe working temperature range is being refined and updated as experience and testing prove the applicability of these slings over various temperatures Anecdotally there are many Twin Path slings operating in the deserts of middle east and there have been no reports of problems Since Slingmax is the manufacturer closest aligned with development of these slings their website should be considered the most current guidance on this subject Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 52 of 108 3 00 2 00 t 009 No Published Data Trend Extrapolated To Higher Temperatures T T T T T T 0 00 T T 1 200 160 120 80 40 0 40 80 120 160 200 FAHRENHEIT Figure 25 Effects of Cold Temperature on K Spec Fiber If slings with a higher temperature rating are required a modification of the TPXC slings is made with a different blend of core fibers is available Sparkea
13. Diameter of cable body 2 IWRC Table 12 OSHA 1926 251 Tables H 11 to H 14 Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 31 of 108 Synthetic Slings Modern polymer and composite materials are rapidly replacing steel for countless tasks and engineered objects High strength synthetic slings are becoming an alternative to wire rope slings as they are lighter generally require less maintenance and are easier to handle This results in a cost savings through the reduction of production rigging time with an increase crane efficiency but this is not the only reason for their wide spread adaptation Synthetic slings are also relatively soft and wide which enables then to be wrapped around cylindrical objects such as rocket boosters or generator turbines that either have delicate and easily damaged surfaces or polished surface finishes that cannot be marred which might happen from a wire rope lift There are two main types of synthetic slings web slings and roundslings Web slings can be characterized as being relatively flat typically being an order of magnitude wider than they are thick These slings are perhaps the most common sling being used by the industry and are available in sizes up to about 50 tons Multiple layers or plys can be added to a sling in order to strengthen it but this can sacrifice flexibility and there is a definite limit as to how
14. Page 36 of 108 Length and Strain Twin Path slings have been made 150 feet long and as short as 18 inches In the past length tolerances were considered to be about plus or minus one half of one inch as described in slingmax s technical bulletin number four Recently this fixed amount has been updated to take into account different manufacturing facilities and the fact that the horizontal manufacturing process must deal with a certain catenary effect that has a greater effect on tolerances of longer slings The current quoted tolerance of a slings loaded length is roughly 1 inch for slings less than 40 foot long 2 inches for 40 to 80 foot lengths and 3 inches for over 80 foot lengths For most sling lengths typically ordered this works out to be less than 0 5 of the overall sling length Slings made at the same time on the same machine by the same operator will usually be much closer in tolerance than the values indicated above If matched length slings are ordered tolerances can usually be created of only 1 4 inch for nearly any length sling Measuring the length of a Twin Path sling can be difficult as how it is taken can significantly affect the stated length The proper measurement of a roundsling must be made of the slings core which resists the loads and not the cover which may be of slightly different and somewhat variable length A nylon cover will be especially likely to affect the measured length and is the m
15. Path slings can also be acquired thought the use of a fiber optics strand laid within the core bundle The use of fiber optics provides an additional and somewhat different protection than the External Warning Indicator Where the EWI s protection is mainly a function of total sling elongation a fiber optic tail provides a better indication of crushing cutting or environmental damage A fiber optic strand acts as a channel or conductor of light which will bounce down its length and through its curves to appear with minimal loss out the other side The transition of light through the core filament of the fiber optics depends on the refraction properties of the coatings on the surface of fiber optic filament If the surface of the fiber optic cable is damaged the amount of light being transmitted though the fiber optic cable will be greatly diminished and if the cable were to part no light will be transmitted at all The fiber optic cable used in Twin Path slings have a polyethylene refractive jacket which aids the detection of chemical exposure or other environmental damage such as temperature on the core bundles This is because many of the temperate and chemicals that effect K Spec fibers will also degrade the polyethylene fiber optic jacket If crushing damage occurs to the core yarns of the Twin Path sling there is a good chance that the fiber optic cable laid within will also be damaged and will no longer transmit light Similarly the wear and
16. a balance of forces about them This is accompanied with sling and block rotation along with translations of a small but important amount the main driver of which is the lowering of the blocks center of gravity These adjustments will have the effect of increasing some sling tensions so an understanding of the probable result along with the estimate of the final stable arrangement should be made An example of this re balancing can be seen in Figure 21 where the initial unstable configuration results in rotations and shifting of the forces carried between members FLOUNDER EQUALIZER h7 STABLE FLOUNDER UNSTABLE FLOUNDER REBALANCING STABLE RIGGING DESIGN RIGGING DESIGN ROTATION amp TRANSITION RESULT Figure 21 Rebalancing of Load and Flounder Plate Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 87 of 108 One of the very first concepts of rigging is that for a single crane lift the center of gravity COG of what is lifted will always end up directly below the hook This concept holds true with flounder plate use and although rigging arrangements can be more forgiving with their use the design of a proper arrangement still requires a reasonable estimation of COG to be made For any arrangement to be stable or lift as intended the center of gravity must be bounded by the attachment locations of the slings as shown in Figure 22
17. and Vestil NASSCO has roughly 24 spreader bars in regular use ranging form 2 5 to 295 short tons lifting capability and form 4 ft to 42 ft in spreadable length The largest spreader bar matches the lifting capability of the largest crane Many of the spreader bars have a unique geometry and lifting attachments to accommodate a large range of lifts All spreader beams have been custom designed in house End Connections Spreader beams are used to spread the load of an object being lifted and they achieve this by different forms of attachments Typical attachments points are hooks permanently secured master links or pin connections for shackles or endless slings Most critical lifts are secured with either padeyes and shackles or pins and endless synthetic slings Standards and Regulations The best standards for spreader beams are the American Society for Mechanical Engineers Below the Hook Lifting Devices Design Guide and associated standard B30 2 Special considerations need to be made during the design of spreader beams as the long life cycle can have significant effect on the design It is possible that during this life cycle they will perform tens of thousands of lifts potentially of unknown loads and variable conditions A respectable design factor should be chosen as bearing wear fatigue corrosion and other effects of ageing that will set in Use or disclosure of data contained on this page is subject to the restriction on the title
18. complicated multi degree of freedom calculations that would need to be done to check the resultant re balancing that occurs This straight forward case can be seen in scenario A which represents the best arrangement as it is the most likely to divide the sling forces equally when tolerances of the slings or COG estimate create slight adjustments and furthermore allows the easiest and most straight forward tabulation of the resulting sling tensions and ease of rigging SCENARIO A SCENARIO B SCENARIO C Figure 24 Flounder Plate Applications Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 90 of 108 Additionally flounder plates are sometimes used directly with a cranes sister hook as a method of attaching a single sling This is typically needed when the sister hook does not have a central attachment point for a single shackle As sister hooks have limitations as to the amount of loading that can be placed on only one side flounders can be used to distribute the load to both sides as shown on the left of Figure 25 Here two large shackles are attached to the flounder plate and looped over each side of the hook In this way a single sling with a relatively large load can be attached to a sister hook while staying within the capacity limits of the hook Figure 25 Flounder Plate Use on a Sister Hook Use or disclosure of data co
19. confidence in their slings These features are especially relevant since unlike many other slings the strength elements are not visible Where slings made of wire ropes can be quickly visually inspected for broken strands the core strength fibers of roundslings are hidden inside the protective cover and cannot be visually inspected in the field The original inspection technique to confirm the soundness of the core fibers is to feel them which takes more time than a visual inspection and requires some knowledge and training as to what the core should feel like The task of feeling the core is especially complicated and subjective since a bulked nylon cover prevents one from directly accessing the core bundles If a core cord were to part during use it would recoil in either direction and most likely end up bunched up near the bearing surface at the time of use This tactile inspection of roundslings is specifically oriented towards looking for tumors knots or hard spots that can result from a parted cord which if present indicate a sling has been severely damaged and should be immediately removed from service Several unique safety an inspection systems have been created to help ensure the strength core of Twin Path sings are fit for use To provide a quicker visual inspection technique Twin Path slings now come with and External Warning Indicator EWI that is designed to notify the user if the sling has been over loaded and may be in danger of fail
20. curvature of the surface that the sling is attached in case D which does not promote uniform bearing pressure Theoretically if the bearing surface is large enough the effects of bearing on a two degree of curvature surface will be negligible as expressed with case B If the curvature of the surface is too severe or the shackle not wide enough the result is bunching which will significantly reduce the strength and useful life of a sling Finally side loading as seen in case E can be detrimental if the bearing forces are high enough as with a small diameter pin This is because it is possible that in this condition only one path of a Twin Path roundsling will be taking most of the Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 46 of 108 load It must be remembered that rigging is a dynamic event that is often pictured and analyzed as quasi static but in reality an angle between a sling and an attachment point will vary by a few degrees as the load is moved so to some extent side loading is inevitable A sling that is side loaded will most likely have a lower breaking strength but the exact limit or maximum safe angle for side loading is unknown It should be noted that side loading is sometimes designed into a sling arrangement with a common example being basket hitches from a duplex hook being spread to either side for better load control as seen
21. flounder plate of the same width For a ten foot sling length the curves can be directly compared in the top two graphs It can be seen that for a given deviation in sling length the high aspect ratio equalizer shares the load more equally It can also be seen that high aspect ratio equalizers are less affected by the separation distance where the slings meet the ship unit block This separation distance DB has effects that can clearly be seen for the lower aspect ratio flounder When the slings are near vertical with a base separation distance of 30 inches a 2 5 deviation in sling length with ten foot slings causes the more heavily loaded sling to take 87 of the total load When the separation distance is 90 inches the same deviation causes the more heavily loaded sling to take 65 of the total load which is a more even load share However this does represent a slightly larger average sling load as the increased angle of the slings results in a greater tension in the slings for the same vertical force Finally Figure 11 shows curves developed for various aspect ratio load sharing devices of similar size such that one can see the effects that aspect ratio has on load sharing ability From this it can clearly be seen that in this application high aspect ratios equalizers are better for sharing the load The main drawback to a high aspect ratio design is that the internal stresses in such an equalizer are much higher and would thus need to be comparat
22. in Figure 15 With a basket hitch however the side loading is usually on an object of considerable diameter or size so the overall bearing pressure is low and the core fibers have space to adjust themselves and promote more uniform loading Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 47 of 108 Rendering When a roundsling is configured for a lift a rigger will try to ensure that the sling is snug and properly attached such that a minimal amount of adjustment will occur as the load is drawn up The adjustment that occurs is often referred to as rendering One side of the endless roundsling will inevitably have extra length that will not fully take load until the sling has equalized itself with both sides being of equal length When this adjustment takes place the cover can often be seen to slide around the pin connection and due to the load in the sling friction abrasion and wear will occur on the bearing surface which can sometimes even produce tears on the bulked nylon Covermax cover It is believed that the incorporation of Cornermax sleeves onto designated bearing points on a Twin Path sling will substantially toughen up these surfaces and significantly reduce the chance for rendering related damage to occur Furthermore rigging practices can be optimized to minimize this effect by attaching the roundsling to the hook first and then pulling the s
23. in the radial plane Often two trunions are used on either side of the center of gravity to facilitate easy rotation of an object They have limited use in large block shipbuilding lifting as multiple lifting points are usually required and in order to structurally integrate trunion into most structure they must be effectively buried making removal difficult Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 9 of 108 Figure 3 Trunion Standards and Regulations There are no published standards specifically applicable to padeyes used for ship construction NAVSEA however has a guidance drawing No 5184133 pertaining to permanently installed padeye for machinery lifting The best document to govern lifting padeye design would be the American Society of Mechanical Engineers Design of Below the Hook Lifting Devices ASME BTH 1 2005 This design standard gives very detailed advice as to the design of single plate pin connections which is the heart of many padeyes The structural design section of this document also gives clear advice as to how to apply recommended design factors to either calculated Von Mises stresses or classically calculated shear or moment forces on different sections Many of the formula prescribed are based on AISC allowable stress design formula with slight modification resulting in increased design factors These have been added to
24. in various configurations for various classifications with hand tucked or mechanical spliced joints for improved plow steel grade rope construction improved steel plow rope and aircraft grade rope Three different arrangements are calculated being a vertical leg looped as a basket and used as a choker The tables give the capacities based on minimum bend radius requirements where applicable TABLE H 11 RATED CAPACITIES FOR STRAND TABLE H 11 RATED CAPACITIES FOR STRAND LAID GROMMET HAND TUCKED LAID GROMMET HAND TUCKED Continued Improved Plow Steel Grade Rope improved Plow Steel Grade Rope TABLE H 11 RATED CAPACITIES FOR STRAND TABLE H 13 RATED CAPACITIES FOR STRAND LAID GROMMET HAND TUCKED Continued LAID ENDLESS SLINGS MECHANICAL JOINT Improved Plow Steel Grade Rope Improved Plow Steel Grade Rope ene shee when the Did ratio is 5 or Siena es meace eau ant ase ot ar dre perl TABLE H 12 RATED CAPACITIES FOR CABLE LAID GROMMET HAND TUCKED T amp T and 76x19 Construction Improved Plow Steel Grade TABLE H 14 RATED CAPACITIES FOR CABLE ste ae LAID ENDLESS SLINGS MECHANICAL JOINT 7x77 and 7x7x19 Construction Galvanized Aircraft Grade Rope 7x6x19 IWRC Construction Improved Plow Steel Grade Rope 1 These values only apply when the Did ratio is 5 or greater D Diameter of curvature around which cable body is bent d Diameter of cable body er whore Bebrarnetey feu around which cable body is bent d
25. into a more perfect alignment in which they share the load better and more evenly thus increasing the breaking strength of the sling Some of this core adjustment most certainly occurs with the proof load to twice the rated load which occurs before a sling leaves the manufacturing plant If additional adjustment is in fact taking place it must be accompanied with some elongation of the total length of the sling whether this is measureable or not is up for debate During Crosby s extremely severe cyclic testing of Twin Path slings documented in technical bulletin 9a they state that the slings appeared to get between 2 5 and 4 longer after the test Riggers at some American shipyards also insist on observed elongations of Twin Path slings after they have been broken in of a much smaller percentage in length but measurable none the less due to the significant lengths often in use Furthermore the longer and higher capacity the sling is the more difficult it is during the manufacturing process to ensure that all yarns are the same length Partially for these reasons it is advisable that slings of similar age and work history be paired together as much as possible especially in applications where equal length parts is an essential ingredient of the rigging design Twisting over Length Most standards explicitly expresses that roundslings should not be twisted or as in the specific wording of ASME the twisting of slings shall be avoided So
26. planned angles or lengths of the slings as shown on the right of Figure 24 These complex lifts typically require alteration of slings lengths possibly due to the asymmetry of the object or obstructions preventing a symmetrical and balanced rigging arrangement Examples of the block geometry preventing the preferred simple arrangement as can be seen in scenario B and C in which the slings are prevented from being the same or approximate equal length If the stable arrangement is easy to calculate and the increased length of sling required small extra shackles can be inserted into the sling to increase it to the required length as shown in scenario B This can typically be calculated through a numerical or iterative application of the elementary principles of statics However this calculation for exact sling length can be fairly complex at times and typically requires a highly accurate estimate of the center of gravity and if an absolutely level lift is required the easiest engineering fallback is to specify that a chain fall be used as seen in scenario C With the use of chain falls the sling lengths can be quickly adjusted in situ to the exact lengths required to ensure a level lift Setting up a chain fall for a large lift can be fairly laborious and typically there is the desire to avoid this especially on large complex lifts Where possible the slings should be kept the same length and evenly spaced on either side of the center of gravity to avoid the
27. reduces the standard deduction The use of the choking hitch also suffers from the long length of sling needed and bearing pressures which will usually be higher than a normal basket hitch This is because the choking nature of the lift causes an additional squeezing pressure which increases the bearing pressure seen at all contact points Also additional planning must be used for choking hitches to ensure the choking action is not on a spliced or tagged area of the sling which may cause local abrasion ASME WSTDA Standard Eye Sling Endless Round Sling Choker Hitch Capacity Adjustment Angle of Choke degrees Choker Hitch Capacity Adjustment Angle of Choke degrees Rated Capacity Rated Capacity Percent Percent 120to 135 120to 135 90 to 120 90 to 120 71 60 to 89 74 60 to 89 58 30 to 59 62 30 to 59 1 te 29 49 1 to 29 Angle of Choke degrees 120to 135 113to 120 103to 113 90 to 103 66 to 90 0 to 66 Rated Capacity Percent Figure 18 Comparison of Reduction Factors for Eye Sling and Endless Roundsling The most common large shipyard rig of endless slings is a vertical hitch which may or may not be vertical in orientation and for large lifts may be arranged with multiple spreader beams cranes hooks and a dozen individual slings The primary reason for the use of so many slin
28. ride loads lifted by roundslings This standard covers the three standard rigging hitches and also covers a approved methods of adjusting the length of the sling For choking hitches this standards has a reduction table that is different than others as the WSTDA believes that endless slings will be subject to additional stresses at the choking point which will further reduce capacity These reductions are in addition to the reduction to 80 of vertical capacity This standard has one of the most comprehensive sections on bearing pressures and requirements for connections It sets a maximum bearing strength of 7 000 psi which should be applied to all pins and edges of loads Worked examples are included for the calculations of bearing strength States that all bearing surfaces should be clean and adequately radiuses to prevent cutting or other forms of damage to the slings A section on effective width of bearing surfaces is included which reduces the bearing area of bowed bearing surfaces such as anchor shackles to 75 the diameter of the bow to account for the localized compression of the sling This value however should not exceed the actual width of the sling States that roundslings shall not be twisted and twisting of the legs should be avoided Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 60 of 108 NAVFAC P307 This extensive Naval Faciliti
29. rigging hardware as light and small as possible One significant desire for lighter rigging equipment is safety as manipulating dense and heavy slings and hardware requires significant effort may be done in awkward or overhead positions all of which results in a greater risk of injury to rigging personnel Furthermore with the desire to minimize equipment handling costs through a reduction of the rigging efforts required significant savings can be realized through the use of these lighter high performance slings A typical high performance Twin Path Extra sling will have only 10 15 of the weight of a comparable wire rope which can be directly correlated to the handling efficiencies that can be gained Although there are many reasons for the adoption of high Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 16 of 108 performance slings the relative lack of detailed standards use guidance and historical anecdotes can create apprehension to their adoption along with their delicate nature and the concealment of the main strength members Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 17 of 108 Wire Rope Modern wire rope is perhaps the most widely used rigging sling material and has been in use for over one hundred and seventy years This long history of use ha
30. these load ratings of Table 4 Shackle Safe Working Loads OSHA based on pin size as there have been much advancement in material technology since the table was formulated The new materials in use still provide a safety factor of 5 as required by the OSHA standards but do so with reduced weight and size Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 15 of 108 3 SLINGS Slings are an important part of rigging as almost all lifts require a flexible temporary link to transmit the loads from the object being lifted to the lifting device or crane Shipyards typically use slings made from chain wire rope or synthetic materials Of these materials wire rope and synthetic slings are the most common for the large lifts in shipyards with high performance synthetics increasingly becoming the dominantly used material Chain slings are perhaps the original high capacity sling material as historically speaking they are much stronger than natural fiber rope Although very resilient with the ability to work in extreme and punishing environments chain slings are generally no longer used as they are the heaviest sling material available imposing significant handling costs Chain slings are however still used as part of chainfalls which allow the sling to be varied in length while under load This significant advantage can provide the small adjustments needed wh
31. title page of this document GENERAL DYNAMICS Page 84 of 108 Single Crane Use of Flounders Lifting an object with a single crane and four slings that are connected rigidly represents a statically indeterminate problem in which the actual vertical component of force in each sling is unknown and can vary from nothing to half of the total load This is because if one sling is slightly longer than the others it will not engage the load and will hang slack This sling s opposite corner attachment will thus similarly be slack as all the moments created about the center of gravity must have a equilibrium maintained This is especially true if the slings are not elastic and do not stretch much under load which is the case for wire rope or high tensile strength synthetic slings such as Twin Path with K Spec This concept is widely understood as a four legged stool or table with one leg longer or shorter than the others which will forever rock back and forth on two legs at opposite corners with these opposite leg pairs taking all the weight This concept as it relates to rigging is shown in Figure 19 where two different possible vertical components of the sling tensions are shown Figure 19 Indeterminate Four Slings Arrangement Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 85 of 108 In rigging flounder plates have traditionally been used as a
32. 010 There are four main chapters in this standard and they are more extensive and detailed than other standards and include specific numbers for many of the recommendations These chapters cover material construction procedures for testing and recommended operating practices Some manufacturers of the Twin Path slings suggest that many of the operating practices laid out in this standard be followed even though this is written for polyester and not K Spec core fibers A rigging engineer or lift designer reviewing this standard might be most interested in specific comments in this chapter on specific limits for roundsling use A brief synopses of some of these important points in the standard are Sets a minimum roundsling design factor of five which is the ratio of minimum breaking strength to rated load A warning is included in this paragraph noting to the user that depending on the bearing pressure present the actual failure load of a sling may be less than the nominal breaking strength of the sling A note in the bearing section suggests that a capacity reduction of 20 may be appropriate depending on the specific requirements desired Furthermore this standard cautions the user that this design factor is the design factor present when the sling is tested in laboratory conditions which are never exactly duplicated in the real world This standard indicates that roundslings should not be used to support personnel platforms or have personnel
33. 1 7x6x19 2 N Tis T719 11 0 Tx6x19 7x719 Tx7x149 7x49 27x6x19 14 0 1 These values only apply when the D d ratio in 10 or great 16 0 er where D Diameter of curvature around which the body of 20 0 a ee ive 1 Va TABLE H 6 RATED CAPACITIES FOR SINGLE LEG SLINGS 8 Part and 6 Part Braided Rope 6x7 and 6x19 Construction Improved Plow Steel Grade Rope 7x7 Construction Galvanized Aircraft Grade Rope Rated capacities tons 2 000 Ib Se eee ee ee ee sling is bent d Diameter of component rope Table 8 OSHA 1926 251 Tables H 5 and H 6 Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 28 of 108 OSHA Table H 7 and Table H 8 gives the rated load capacities for 2 and 3 leg bridle slings arrangements for improved plow grade rope with fiber core or wire core based on the ropes classification The tables give the capacities based on a termination of a mechanical splice or hand tucked splice TABLE H 7 RATED CAPACITIES FOR 2 LEG AND 3 LEG BRIDLE SLINGS Continued 6x19 and 6x37 Classification improved Plow Steel Grade Rope With Fiber Core FC TABLE H 8 RATED CAPACITIES FOR 2 LEG AND 3 LEG BRIDLE SLINGS 6x19 and 6x37 Classification Improved Plow Steel Grade Rope With Independent Wire Rope Core IWRC Rated capacities tons 2 000 Ib 2 leg bridle slings pare Soe oor peers Table 9 OSHA 1926 251 Tables H 7 and H 8 Us
34. 108 cyclic tests conducted in August of 2006 The Crosby Group Laboratories conducted cyclic testing of four foot long Twin Path slings to 150 of their rated load using a bolt shackle that had a rating similar to the sling The bow of the shackle was polished to a smooth finish to promote a uniform bearing pressure of approximately 4 500 pounds per square inch The test was conducted on three different slings at different cyclic frequencies one at two Hz and two at four Hz Each of the three samples was tested for over 50 000 loading cycles No sling failed during the test however all slings showed hardening of the cover and core fibers around the bearing area One of the tested slings was destructively tested afterwards and failed at four times its rated capacity showing it maintained a significant strength reserve above its original rated capacity Additional details about these tests can be seen in Slingmax technical bulletin number 9A B 9 13 BOOR UOR OOOO PFW eee Oe i ao Figure 20 Cyclically Tested Twin Path Test Slings A similar fatigue test was conducted on a six foot long TPXC sling in October of 1997 by Tension Member Technology This test had one key difference in that instead of the curved bow of an anchor shackle a straight pin was used The calculated bearing pressure during the tes
35. 3 et ea eae MASTER LINK MASTER LINK MASTER LINK Zz LB WLL 160000 LB WLL 143100 LB WLL 102600 LB WT BB LB WT 68 LB WT 54 LB WT 37 LB Figure 4 Selection of Typical Shackles and Rings Loading Restrictions and Recommendations The most ideal way to load the pins of shackles is with a uniform section that is 80 as wide as the opening of the shackle This loading method will reduce the bending moment on the pin Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 11 of 108 CROSBY SHACKLES POINT LOADING POINT LOADING OF CROSBY T SHACKLE BOWS IS ACCEPTABLE POINT LOADING OF CROSBY SHACKLE PINS IS ACCEPTABLE O AS LONG AS LOAD IS lt gt REASONABLY CENTERED ON THE PIN ALTHOUGH POINT LOADING IS ACCEPTABLE A PAD EYE WIDTH OF 80 OR MORE OF SHACKLE SPREAD IS BEST PRACTICE Figure 5 Recommended Distributed Loading of Shackle Pins Figure reprinted with permission from the CROSBY GROUP Shackles will have their greatest strength when loaded in line such that the load will be evenly divided on both halves with minimal bending when transferred back to the pin connection When multiple lines are connected to the same shackle there will inevitably be some angle between the loads and thus they will not be in line with the ideal loading condition If the angle the loads are applied to the shackle is taken to an extreme with the angle be
36. 6 0 17 0 10 0 12 0 13 0 28 0 35 0 158 6x37 16 0 18 0 21 0 12 0 14 0 15 0 33 0 41 0 1 6x37 19 0 21 0 24 0 14 0 16 0 18 0 38 0 43 0 2 6x37 25 0 28 0 31 0 18 0 21 0 23 0 49 0 62 0 1 These values only apply when the D d ratio for HT slings is 10 or greater and for MS and S Slings is 20 or greater where D Diameter of curvature around which the body of the sling is bent d Diameter of rope HT Hand Tucked Splice and Hidden Tuck Splice For hidden tuck splice IWRC use values in HT columns MS Mechanical Splice S Swaged or Zinc Poured Socket 6x19 AND 6x37 CLASSIFICATION IMPROVED PLOW STEEL GRADE ROPE WITH INDEPENDENT WIRE ROPE CORE IWRC TABLE H 4 RATED CAPACITIES FOR SINGLE LEG SLINGS Rope Rated capacities tons 2 000 Ib Di Vertical Choker Bios Constr aind HT MS s HT MS s s Va 6x19 0 53 0 56 0 59 0 40 0 42 0 44 1 2 he 6x19 0 81 0 87 0 92 0 61 0 65 0 69 1 8 6x19 1 1 1 2 1 3 0 86 0 93 0 98 2 6 The 6x19 15 17 18 12 13 13 3 5 v 6x19 2 0 22 23 15 1 6 17 46 Ne 6x19 25 27 29 18 24 22 5 8 5e 6x19 3 0 34 3 6 22 25 27 7 2 Ya 6x19 42 49 5 1 3 1 3 6 3 8 10 0 Ta 6x19 55 6 6 6 9 4i 49 5 2 14 0 1 6x19 72 85 9 0 54 64 67 18 0 1 6x19 9 0 10 0 11 0 68 78 85 23 0 114 6x37 10 0 12 0 13 0 79 9 2 99 26 0 1 6x37 13 0 15 0 16 0 9 6 11 0 12 0 32 0 1 6x37 15 0 17 0 19 0 11 0 13 0 14 0 38 0 158 6x37 18 0 20 0 22 0 13 0 15 0 17 0 44 0 1 6x37 20 0 24 0 26 0 15 0 18 0 19 0 51 0 2 6x37 26 0 30 0 33 0 20 0 23 0 25 0 66 0
37. CS Page 98 of 108 Roller Spreader Beams NASSCO has four beams that are referred to as roller beam bars with lifting capabilities of 99 124 141 173 short tons and respectively 12ft 8ft 20ft and 12 feet in length These beams are essentially an l beam with padeyes attached on both top and bottom located on roughly every 5 ft Figure 33 Roller Spreader Beam Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 99 of 108 Single Web Girder Spreader Beams NASSCO has three Single Web Girder Bars with lift capabilities of 40 70 and 80 ton and lengths of 45 feet These spreader bars are capable of many different lift arrangements and can be used as equalizers Figure 28 shows a load rating for many different typical lifting arrangements Figure 34 Single Web Girder Spreader Beam Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 100 of 108 7 HOOKS In almost all lifting arrangements a hook is used somewhere Typically for most critical lifts the hook that is used in on the crane and has a rating greater than that of the crane It is however important to know some of the loading restrictions that hooks have Hooks used in rigging have been used as long as lifts have been needed and standard shapes and sizes have been established Size and Strength Table 16 b
38. D TYP TOP j ARRANGEMENT FOR 6 ADJUSTMENT FROM 45 00 MINIMUM SLING ANGLE TYP f 38 TO 65 j p 02 25 5 13 TYP BOTTOM 6 00 780 00 MAXIMUM EXTENSION p J E j i 456 00 MINIMUM EXTENSION Figure 31 Telescoping Spreader Beam Figure reprinted with permission from Tandemloc Inc A similar concept to the telescoping spreader beam is modular spreader beams which have bolt together sections that can be added or removed to vary the length of the beam Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 97 of 108 Equalizer Plate Clamp Spreader Beam Three Equalizer Type bars with 30 35 and 64 ton ratings spreading 17 35 and 42 ft These bars have two top attachments and permanent chain attachments with plate clamps underneath located on average every 3 ft The ones at NASSCO are designed to be used with plate clamps to equally spread the load out over a large area This is particularly useful if lifting large plates that are not well stiffened and required multiple pick points Figure 32 Plate Clamp Equalizer Spreader Beam Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMI
39. L DB 3 75xL DB 2 5xL DB 2 5xL DB 1 25xL DB 1 25xL 2 4 69 a a 3 a a Qa 65 z FOE Gi 79 75 75 89 89 85 85 Figure 9 High Aspect Equalizer Plate of Minimal Length Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 76 of 108 T L D 0 57 L 24 Sling Length 6 2xL L D 0 57 Difference of Sling Length SlingLength 6 2xL L D 5 70 Difference of Sling Length 10 00 7 50 5 00 2 50 0 00 250 5 00 7 50 10 00 10 00 7 50 5 00 250 0 00 250 5 00 7 50 10 00 45 DB 3 75xL DB 3 75xL 50 DB 2 5xL DB 2 5xL DB 1 25xL DB 1 25xL HA 690 2 65 Es f 9 x Gi 709 75 89 85 85 Sling Length 11 2 xL L D 0 57 SlingLength 11 2xL L D 5 70 Difference of Sling Length Difference of Sling Length 10 00 7 50 5 00 2 50 0 00 250 5 00 7 50 10 00 10 00 7 50 5 00 2 50 0 00 250 5 00 7 50 10 00 45 45 DB 3 75xL DB 3 75xL 50 DB 2 5xL DB 2 5xL DB 1 25xL DB 1 25xL H 60 A a a 65 Ed a e x 790 75 89 85 85 Sling Length 21 2xL L D 0 57 SlingLength 21
40. ON Figure 15 Load Redistribution During Turn as a Result of Attachment Point Height Variance Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 82 of 108 Whenever possible one should strive for a design that is balanced at all times and will not experience a variance in the required sling length that translates to different and increased sling tensions These effects can be eliminated if all attachment points occupy the exact same axis so that the centers of all pin connections that experience rotation during the turn are collinear Furthermore this effect will be minimized if the aspect ratio of the equalizer is high because this geometric configuration allows the most forgiveness in this application due to the larger rotation sweep and subsequent equalization range In cases where significant sling adjustment will occur during the lift it may be possible to pre load the side that will experience load relief to minimize loading variation The concept of this pre loading can be seen in Error Reference source not found Figure 16 Figure 16 Load Redistribution During Turn as a Result of Attachment Point Height Variance Equalizer and flounder principles can also be applied to large gantry cranes which can effectively be compared to multiple cranes acting together in which equalizers with flounders are used upside down to lift small but heavy objects Figu
41. OSHA standards repeatedly refers an employer to the guidelines set by the manufacturer of any product in question as any standard cannot always be kept abreast of manufacturing updates and thus may be incomplete The Code of Federal Regulations CFR Title 29 Section 1910 is the main regulatory law for which compliance must be in accordance with This section also sets part 1926 to be additional standards pertaining to construction work and sets part 1915 to be additional standards pertaining to shipyard work Within this main part section 1910 184 covers slings with topic h dealing specifically with Synthetic slings Although this standard has no guidance for roundsling use of any type a rigging engineer or lift designer may be interested in certain comments in this part defining some of the limits of natural and synthetic rope slings A brief synopses of some of these interesting points are Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 56 of 108 Depending on the type of rigging operation sets a minimum diameter of curvature related to bearing area for fiber rope slings of either double or eight times the rope diameter in Figures N 184 3 and 4 Allows angles of 5 or less to be considered to be vertical for natural or synthetic fiber slings Defines a safe operating temperature of 20 F to 180 F for natural and synthetic fiber rope slin
42. Production Process Panel Planning Production Process amp Facilities Panel SHIPYARD RIGGING COMMON COMPONENT CATALOG National Steel and Shipbuilding Company Initial Design amp Naval Architecture Originally Issued JULY 2009 Update May 2011 Revision A Category B Data Unlimited Rights NSRP ASE NASSCO ENGINEERING GENERAL DYNAMICS A GENERAL DYNAMICS COMPANY Authors Note This document may at times repeats information that is in different sections and also with information the other accompanying documents Such repetition is by design to present the reviewer of any particular section with relevant information It is seen as preferable to repeat information rather than have that information overlooked This document has information for many of the rigging components commonly used in a shipyard and is intended to provide relevant information for the design of critical lifts using these components It should be noted that no catalog can be complete and cover all information needed all manufacturers or any set circumstance and thorough Engineering review should be undertaken whenever the well being of personnel or property is endangered Proper analysis of stresses within ships blocks during rigging lifting arrangements requires significant experience and detailed knowledge to approximate solutions Although these documents provide a small foundation for the information needed for the design of critical lifts it i
43. able 12 OSHA 1926 251 Tables H 11 to H 14 esesesesrsessesessereserrersresrrsrresrrsseersesee 31 Table 13 Load Ratings based on Chain Dimensions ssssesesssesessseessresseessesssseessseressre 62 Table 14 Temperature based Chain Rating esseesesrsssesreesreeresresstrsrerrersrrsrrsreeserseesreesee 63 Table 15 1926 251 OSHA 1926 251 Table H 1 and H 2 Chain Slings 0 0 0 eee 65 Table TO Hook Working Limits secre e e E E E E 101 Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 5 of 108 OVERVIEW A qualified Rigging Engineer at a shipyard needs to know information about ship structure yard practices procedures and capabilities in addition to having a solid grasp of Rigging Engineering fundamentals The goal of this catalog is to give an Engineer a list of common parts regulations and restrictions regarding these practices general engineering data useful for using rigging components and descriptions as to how these parts are used and interface with each other This is intended to complement the Lift Check Sheet and the Lift Approach Guidance document with additional manufacturer and item specific information The following items are included PADEYES SHACKLES MASTER LINK RINGS SLINGS wire rope synthetic amp chain CHAIN FALLS AIR HOISTS FLOUNDER PLATES AND EQUALIZERS SPREADER BEAMS HOOKS CRANES Ideally every shipyard shoul
44. abrasion of the core fibers that occurs over time will similarly abrade the fiber optics polyethylene jacket providing a user with an indication that the slings useful life may be coming to an end Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 51 of 108 ener ae 7 Jeast Jeast Vrasy v ea Se eor Figure 24 Check Fast Tell tail Temperature Considerations Synthetic sling fibers are plastics which are more effected by temperature than metals over an even narrower temperature range Typically plastics are harder and stronger at colder temperatures and more elastic and weaker at elevated temperatures The brittle properties at cold temperatures that some plastics possess is of special concern for rigging equipment as the sudden quick failure that results may be unexpected and occur with little warning Slingmax tested the core fibers of Twin Path slings the K Spec filaments at different low temperatures to estimate these environmental effects These results show that the fibers got approximately 25 stiffer and over 30 stronger at extremely low temperatures and no brittle failure occurred The results and a description of this test can be seen in Technical Bulletin 34 and a plot of the results in Figure 25 This figure is shows a plot of break strength against temperature with the design factored strength normalized against the
45. al wire rope or chain in that they result in a connection between metallic and non metallic parts This is noteworthy since to date nearly 100 of all synthetic sling failures have been caused by the inadvertent cutting of the strength fibers For synthetic roundslings there are fewer types of connections or terminations than wire rope and most are based on the loop of sling especially for high capacity usage The three common types of hitches usually listed by manufacturers can be seen in Figure 17 The basket hitch shown on the left of Figure 17 is the most efficient use of an endless sling as it is essentially like having two slings with the load divided between them The two main drawbacks to this type of hitch is the very long length of sling typically required and that special care must be taken when setting the load down as the sling must not be pinched under the load This effectively eliminates this hitch for many ship unit erections Additionally careful attention must be paid to the bearing points at all corners of the object being lifted as each location will have an associated bearing pressure which may cut or damage the sling Mu amp Figure 17 Three Main Sling Hitches Basket Vertical and Choker A choker hitch is similar to the basket hitch but is actually the least efficient lifting methodology as the strength of the sling is reduced both geometrically and due to the choking action o
46. allow for the increased failure consequences rigging items face Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 10 of 108 2 SHACKLES MASTER LINK RINGS The most common types of rigging hardware are shackles and rings which allow different components to be attached together As key links in any rigging arrangement it is important to understand how they should be loaded and what their limitations are Different manufactures have slightly different recommendations so specific requirements for a given shackle should be confirmed with the manufacturer Manufacturers The main shackle provider for rigging equipment for large lifts is Crosby Skookum is another major US shackle provider NASSCO primarily uses these manufacturers as a source for shackles Other manufactures of shackle certainly do exist and can provide shackle functionally similar to them These manufactures include Chicago Hardware and Fixture Van Beest Yoke Suncore Sea Fit LGH Lifting Gear Hire BLB Superstorre Bishop Lifting products Taylor Chain KWS Thiele and Hale Iron A Gl Q i O HI SKOOKUM CROSBY SKOOKUM 125TON SHACKLE 82 TON 85 TON 104 TON WT 161 LB WT SOLB WT 96LB WT 1 1 5LB A Fan J K ad ia B 23 23 Qi
47. and preferably have the COG equal distance between sling attachment points lt NOT IDEAL gt Figure 22 Flounder Plates Use Still Requires Good Estimation of the Center of Gravity Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 88 of 108 It is inevitable that some inaccuracy results when estimating the center of gravity of an object which can be considered an offset between its predicted and actual position Along with the design of the rigging arrangement the shape of the flounder plates has a significant effect as to how well the slings forces are balanced and the resultant angle of the lift Flounder plates that have a low aspect ratio as shown on the left in Figure 23 will typically result in lower sling tensions and less angular rotation of the object lifted due to an offset of the estimated center of gravity It therefore can be readily concluded that flounder plates with low aspect ratios are better for use on single crane lifts FFSE Figure 23 Inaccuracy in COG Estimation Results in Rotations Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 89 of 108 Some rigging arrangements are more susceptible to lifting adjustments particularly when there are significant differences in the
48. bers of a Roundsling eeeeecereereerrereene 48 Figure 23 Dyneema bearing Sleeve nsii a a ee Eno E ER E E 50 Figure 24 Ch ck Fast Telltale e ir A R 52 Figure 25 Effects of Cold Temperature on K Spec Fiber cece eee eesecseeeeeeeeeeeenneen 53 Figure 26 Corners and Chain seseseeseesesesessessresresresstssrertessetstssrensttsteeresstestrsresseeseseeeste 63 Figure 27 100 Short Ton Manual Chain fall 25 ssccsccssccseeseesseesasensneesenesacersseczeecenasenes 67 Figure 28 Typical Spreader Beam Allowable Load Guidance 0 0 0 0 eee eeeeeeeeeeneeeneeee 94 Figure 29 Adjustable Box Bar Spreader Beam eeeeeeesceeeeeeeeeeceaeceeeeseeeeaeesaeens 95 Figure 30 Round Bar Spreader Beam eseeeeeseseeseeseereereesersrerresserseesreesrestrsrreseesseseresee 96 Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 4 of 108 Figure 31 Telescoping Spreader Beant isccccseciccnectescecccsdecuedersnctedceosseceadeasucessteavedelnnateaeeie 97 Figure 32 Plate Clamp Equalizer Spreader Beam ec eeseeseeeseeesseeceeeceseeeseeeeneeenaeens 98 Fipure 33 Roller Spreader Bedi jsivederctevsgsvvsscereneses antemercsciees Rveeieadsuautrereaieeeened 99 Figure 34 Single Web Girder Spreader Beam 00 ces cesceseceeeneeceeeceseeeseeeeseesnaeenseeees 100 Fig re 33 Use of HOOKS ccssnscospasapavassnanenseansvxoanpeosaseetomnadananraavtedie
49. bles This table includes the standard deduction in with the angle deduction and essentially used the standard deduction of 80 vertical rated load for choking angles larger than 120 and an increased deduction of 75 vertical rated load for choking angles smaller than 120 in addition to the standard deduction which is a sine function of the choking angle This requires that roundslings with core yarns other than nylon or polyester shall have the pin diameter used for the proof test indicated on the slings certificate and furthermore that this sling never be used on a pin of smaller diameter than used for the proof test Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 61 of 108 Chain Slings Manufactures Rigging chain is required by regulation to be of a higher grade of material This limits the availability of suitable chain to certain manufactures Some of the common manufactures of rigging grade chain are Crosby KWS Thiele Pewag and Laclede Strength and Strain As with many rigging products toughness or ability to be overloaded without sudden brittle failure is required For this reason only alloy steel chain of grade 80 and 100 should be used Alloy chain or suitable grade 80 or 100 will be marked and sold as 8 80 or 800 or 10 100 or 1000 respectively Chain used as a sling should have a design factor of 4 and manufactures load ratings sho
50. bpart f deals specifically hooks Safety factor for hooks is listed as the following 2 The manufacturer s recommendations shall be followed in determining the safe working loads of the various sizes and types of specific and identifiable hooks All hooks for which no applicable manufacturer s recommendations are available shall be tested to twice the intended safe working load before they are initially put into use The employer shall maintain a record of the dates and results of such tests Additional standards for hooks can be referenced in ASME B30 10 2005 Hooks Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 103 of 108 8 CRANES Cranes are required for lifting items in a shipyard Typically for most large critical lifts the cranes used are relatively unique and not mass produced off the shelf items Shipyards should have thorough documentation created with regards to the extent of the cranes capabilities Standard types Cranes are mechanical devices which are used to lower lift and move horizontally material Cranes come in different varieties mobile crawler wheel mounted gantry and overhead cranes Gantry Gantry Cranes consist of a hoist in a trolley which runs horizontally along a rail or a pair of rails fitted under a beam The crane can move along the rails and typically has a hook or set of hooks These cranes can also be mo
51. bution of load among them The result in this extreme case would be that several components from the block padeye shackles and might see as much as twice as much load as the ideal or planned scenario Furthermore not only will the padeye on the block see much more overall load but the angle at which the tension is applied will result in a greater amount of side load which can be very detrimental UNSTABLE FLOUNDER RESULTING REBALANCING OF MOMENT RIGGING DESIGN CHANGES CALCULATED FORCES Figure 13 Poorly Configured Equalizer Arrangement Beneath Spreader Beam Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 80 of 108 The best geometry for a load sharing device below a spreader beam is one with a high aspect ratio as this can be shown to share the load the most equally among all the slings A depiction of this can be seen in Figure 14 where the top two graphics show an idealized lift of a two dimensional structure and the bottom two graphics show what will happen when the far right sling is made two percent longer Although in both cases it results in a slight rotation of the block along with rotation of the equalizer it can clearly be seen through review of the line of action of the slings that that the low aspect ratio equalizer on the left produced the most concentration and increase of individual sling tensions Extrapolation of this concept to a three di
52. cally larger size and aspect ratio associated with it L D KEY L D 1 22 Figure 4 Typical Flounder Plate Made For Crane Hook left L D 3 54 L 84 Figure 5 Typical Equalizer Beam Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 71 of 108 Given the variability of items that require lifting at shipyards there is a wide range of flounder plates and equalizer beams available A parametric study of flounder plates and typical equalizer beams found at shipyards combined with commercially available systems was compiled and can be seen in Figure 6 From this presentation of characteristics the main geometric distinction of the overall size and aspect ratio between flounder plates and equalizer beams is more visible As it will be explained in further detail the reason for two relatively distinct groups is directly related to their best use Flounder plates generally have a low aspect ratio that is ideally suited for single crane lifts attached directly to the hook As a result they tend to be smaller with typically no more than 30 inches separating the attachment points and an aspect ratio of less than two Equalizer beams which are better suited for complex multiple crane rigging operations tend to be much larger in length with sizes greater than 80 inches being common and also have larger aspect ratios tha
53. chemical and environmental considerations for nylon is as follows Nylon is affected by most acids and bleaching agents Hydrochloric acids and Sulfuric acids even in deluded form even can cause a significant loss of strength A 10 concentration of hydrochloric acid and sulfuric acid at room temperature will cause a noticeable loss in strength Some of the chemicals which act as solvents for nylon are formic acid phenolic compounds calcium chloride zinc chloride benzyl alcohol and methanol Nylon looses 15 strength when wet Nylon is not significantly affected by greases oil hydrocarbons aldehydes alkalis Over time nylon webbing will shrink when not used the webbing will shrink 5 of its length When webbing is knitted tightly it will shrink less compared to when it is loosely knitted Humidity and temperature has an effect on the shrinking rate At working load limit nylon will stretch 6 8 however when new elongation will be larger until broken in Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 54 of 108 Polyester Some rigging operations request Twin Path slings with polyester covers The cover should be chosen based on what is considered to be the best material for the job Polyester is a common material for rigging slings with a long history of use and significant data available A brief overview of chemical and environmental considera
54. crushing bunching or restricting the roundslings attachment This section also indicates that the shape of the bearing surface can affect the strength of the roundsling but does not define a maximum recommended pressure Indicates that unprotected shackle pins may damage a roundsling and should be avoided with protection added to protect the sling The standard indicated that both the static and dynamic loads expected must be below the rated load The standard indicates that slings and their fittings shall be compatible with regards to load rating such that the rating of the union is the lesser of the two States that slings should not be twisted and that twisting of slings should be avoided Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 59 of 108 WSTDA The Web Sling and Tie Down Association WSTDA is an organization of sling manufacturers and industry that is intended to promote quality and safety through the creation of voluntary standards and reference material The standards it creates are almost entirely related to the manufacturing process and use of synthetic slings This organization has a standard for polyester roundslings WSTDA RS 1 which covers basic definitions and manufacturing requirements for these slings and also has guidance for the proper use of these slings This standard has several revisions and was most recently revised in 2
55. csssensscssccssscssnasscesasssscasseesconsascesgsssecsosscanccostsssccasscsscesssess sessesessessasessssesasensssase Wire TOG sass scassnaceanaitcevninaacsaoenseaa ele creas vin edseoni arn EE aaia 18 IPM AUNTS snno E a E E E E T ERR 18 Strength and Selection sssini arn aii esaeen i i 18 Measured Length ssssresirisisrssicsinasisiiniisisiiii sinnini anie a Eesaia 19 Stain and Mod l Sisesti reiecit eaa ae a aaa aaa a a a Eaa 20 E d COMMS CUS oisein a a a a a a 21 Bend RadiUSsunonieneeas a E AN A A E 24 Standards and Regulations sseeeseseeseeseessreesesrrsstsrrssrtsstserestesseterestessetstesreeseeseeeressre 26 Synthetic Slings sa case esc ccssvsiieccvasa ceaesanceidacsivnsg cca abedeinn aes evndeeebadSaeeav aden aden 32 Twin Path Slingmax Sparkeaters K Spec Covermax are registered trademarks of Sr TTS NN cessere nsii E ESA EE Eaa E eE ea SEa Esi 33 WAAC UTS eccoge a AEE ee 35 General Construction sicssessecssnterncnioconnedncnamimnnvoimadannomuwsaine 35 Strength nenii so ee ea ee E 36 Length and SOP AMI asp inca scasdeiacdosuansesarcesaseadwesaes E AE E RES 37 Construction stretch oc ssa cesasscsaisnenvsiesateunuria tansinsasten guanedovadoss snuvaatarupacsiasumeaoeeduecaieny 39 Twisting oyer ToS UN oie pteaidctn ie dccos oie oaheelaeedene ie ee 40 End Connections enc sccenenoniecden nee enone enema 41 MRM CUE E NING ais cuss siesena aria ae e a saaa 48 Wear Protec honreereiiceriei i i o A 49 Inspection and Safety Features 00 0nno
56. d have a catalog of its own equipment integrated into an extensive library of acceptable arrangements and loads This will reduce the time spent on the non value added work of figuring out lift arrangements and what are acceptable limits for individual components in such an arrangement This is beneficial for training new employees or used as a collaborating reference for seasoned ones all of which will allow the work load to be better distributed during times of high demand These catalogs of relevant information should be geared towards increasing the learning curve and improving the efficiency of employees A catalog of common shipyards components that are used for lifts can quickly become quite extensive as significant amounts of information can be generated and accumulated It is important to keep a specific focus on items added to this catalog with a regard to what is relevant information It is suggested that the item specific information in a catalog of critical components includes the following L Manufacturers of such components should be cataloged such that one can always contact the source directly if a question prompts the need for more detailed or current information Also comparisons can quickly be made with similar parts that may provide a better solution for a particular arrangement Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 6 of 108
57. degrees Percent Figure 9 Choker Hitch Efficiency Figure reprinted with permission from the WIRE ROPE TECHNICAL BOARD The termination efficiency of an eye at the end of a wire rope can be compromised if the diameter of the attachment piece is either to large or too small If the pin passing through the eye is too large the eye will be subject to splitting where the two sides of the eye reconnect and failure will occur Conversely if the pin if too small the strength will also be reduced A pin of equal diameter to the rope size will effectively create a D d ratio of one reducing the efficiency of each part by 50 The fatigue life of a wire rope is also greatly dependant on the bend radius that it is subjected A wire rope subject to this type of loading with a D d ratio approaching unity will have very minimal fatigue life somewhat depending on the type of rope Ropes subjected to this severe loading condition should be thoroughly inspected after every use 8x d THE WIDTH OF A STANDARD LOOP SHOULD BE 8 TIMES THE ROPE DIAMETER THE LOOP LENGTH OF A STANDARD LOOP SHOULD BE 16 TIMES THE ROPE DIAMETER A N A PIN SHOULD NOT BE LARGER THAN 1 3 THE LOOP LENGTH OR SPLITTING OF THE EYE WILL OCCUR A PIN SHOULD NOT BE LESS THAN THE WIRE DIAMETER OR BENDING FAILURE IN THE EYE WILL OCCUR IN ADDITION TO SIGNIFICANTLY REDUCED FATIGUE LIFE Figure 10 Relationship Between Pin Size and Wire Rope Loop Use or disclos
58. e or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 29 of 108 OSHA Table H 9 and Table H 10 gives the rated load capacities for 2 and 3 leg bridle slings arrangements for improved plow grade rope and aircraft grade rope The tables give the capacities based on an assumed termination of a mechanical splice TABLE H 9 RATED CAPACITIES FOR 2 LEG AND 3 LEG BRIDLE SLINGS Cable Laid Rope Mechanical Splice Only 7x7x7 and 7x7x19 Construction Galvanized Aircraft Grade Rope 7x6x19 IWRC Construction Improved Plow Steel Grade Rope ae tons 2 000 Ib Table 10 OSHA 1926 251 Tables H 9 TABLE H 9 RATED CAPACITIES FOR 2 LEG AND 3 LEG BRIDLE SLINGS Continued Cable Laid Rope Mechanical Splice Only 7x7x7 and 7x7x19 Construction Galvanized Aircraft Grade Rope 7x x19 IWRC Construction Improved Plow Stee Grade Rope iapa TABLE H 10 RATED CAPACITIES FOR 2 LEG AND 3 LEG BRIDLE SLINGS 8 Part and 6 Part Braided Rope 6x7 and 6x19 Construction improved Plow Steel Grade Rope 7x7 Construction Galvanized Aircraft Grade Rope Rated capacities tons 2 000 Ib Table 11 OSHA 1926 251 Tables H 9 to H 10 Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 30 of 108 OSHA Table H 11 through Table H 14 gives the rated capabilities for continuous loops of wire rope
59. e through the course of the lift This is especially true during turning operations as seen in Figure 15 which shows a depiction of a highly cambered deck being flipped Although the sling lengths are initially set such that they all equally sharing the load the act of block rotation alters the relative heights of the attachment points This effectively causes the sling lengths to change which results in the load no longer being shared the same In this exaggerated case it can be seen that after the block has been rotated from upside down to ships position the inside slings are now slack and carry no load This results in the outer slings taking the entire load which is more than twice the original tension increased slightly due to the slings vertical angle change The result in this extreme case would be that several components from the block padeye shackles and might see as much as twice as much load as the ideal or planned scenario Furthermore not only will the padeye see an increase of overall load but the increased angle at which the tension is applied will result in a greater amount of side load which can be very detrimental This example is shown with a relatively extreme camber on the deck which requires the load sharing devices to make up a greater adjustment of sling length Most vessels will not have such extreme camber so the effect will be less but still requires review and consideration UPSIDE DOWN BUILD POSITION SHIPS POSITI
60. e untrue significant deviations would alter the declivity of the block below and the assumptions would lose validity As the block is not expected to deviate from roughly horizontal it can be assumed that the load on the top of the flounder plate is always in the vertical direction and the sling attachment points at the bottom of the system do not rotate relative to each other This system shown in Figure 8 can then be readily solved with trigonometric identities or through the use of numerical modeling resulting in curves like that seen in Figure 9 Figure 10 and Figure 11 These curves of load sharing are valid when based on the analysis of two equalizing plates used under a spreader beam as used in some large complex rigging arrangements Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 73 of 108 Figure 8 Free Body of Load Share Problem The equation describing the system shown in Figure 8 are 5X F 0 F cos 4 F cos A gt F 0 Fsin A F sin A YM Lud TopHole 0 E Deosts sna bina P Leos costs Dsin A feos L L P F eosta Dsin A feos FD cos 4 sin 4 smn 4 0 2 X Geometric Horizontal 0 DB L cos A S sin 4 9 sin 4 ps Yoeometric Vertical T 0 Si cos 4 L sin 4 S3 cos A From these equations curves were developed and represent the load sharing betwee
61. e with FC Wire Rope Socket Spelter or Resin 100 100 Swaged Socket Regular Lay Ropes Only 100 Not Recommended Mechanical Spliced Sleeve Flemish Eye 1 dia and smaller 95 92 1 2 Greater than 1 dia through 2 92 1 2 90 Greater than 2 dia through 3 1 2 90 Not established Loop or Thimble Splice Hand Spliced Tucked Carbon Steel Rope 1 4 90 90 5 16 89 89 3 8 88 88 7 16 87 87 1 2 86 86 5 8 84 84 3 4 82 82 7 8 thru 2 1 2 80 80 Loop or Thimble Splice Hand Spliced Tucked Stainless Steel Rope 1 4 80 5 16 719 3 8 78 7 16 771 1 2 76 5 8 74 3 4 72 7 8 70 Wedge Sockets Depending on Design 75 to 80 75 to 80 Clips Number of clips varies with size of rope 80 80 IWRC Independent Wire Rope Core FC Fiber Core Typical values when terminations are correctly designed applied and maintained Refer to fittings manufacturers for exact values and method Table 6 Terminal Efficiencies Approximate Efficiencies are applicable to the rope s minimum breaking force WIRE ROPE TECHNICAL BOARD Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 23 of 108 Bend Radius Wire rope is often wrapped under a load and at the corners subject to being wrapped at a given bend radius The size of this bend radius is critical with regards to the strength of the rope The
62. eeeeesensseeseeseesseeseesesssressesetsseessessessresseeet 50 Temperature Considerations cccccccccccceescecssseecesseeceseeeceeeecsseeecsseeeesseeecsaes 52 Chemical and Environmental Considerations ccccccccsssecesseeeeseeeesseees 54 Chain SINS eieae aeaa iaae aea aeai ai 62 WIA ACTIN CS 55552 danccsienaty eens eto saree 62 Strength and SSOPAUIN sos cdcs cased pdactaaedzsn sta rasteaccwaedaswd aguedeagetenaebeawienaecestedostacdonaacaet 62 End Connections oc soccscesvsesssnescisaiteincaastens tase ealeanavaedasieentenieeneaieinmdanes 64 Standards and Regulations 0 ccccccceccceseceeeeeeseeesceceaeceeeeeeaeecaeecaeeneeeeeaeeeaees 64 4 CHAIN FALLS AND AIR HOISTS siscsscccscessccssesssonssccssecsssessevsscosseoscoacconscseesavcseecserscsssorsssoscossoossos sues S V A EE nana A N esann 67 End Connections 52 o205censrapescsrdanessoiaeotnid caesar 67 Standards and Regulations cccccccssecesssecesscecesseecesceecsseeecseeecsseeecseeeesseees 67 5 FLOUNDER PLATES AND EQUALIZERS cscccssssscesssscsssssssesccosssescossscsscnssscsscnesscessesssesasssseassenssoase Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 3 of 108 Load Sharing Rigging Device Overview csssscsccssssceccssssccccanssccccassssccacssceccacsseeccocsseseeacsseeeeauens 6 SPREADER BEAMS sisscessiisscossiissonssiccsenssssccte
63. eing lifted This allows erected blocks to be aligned precisely in their final ships position before being released by the crane Also tolerance critical items such as shafting or propellers can be leveled and installed precisely These rigging tools are used extensively in shipyards for block and equipment lifting arrangements Manufactures There are many manufactures of chain falls and air hoists Some popular makers are Ingersoll Rand J D Neuhaus Harrington Hoist and Cranes Budgit Coffing and Yale Most typical sizes are less than ten tones but larger models are made for large lifts such that take place in shipyards Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 66 of 108 Figure 27 100 Short Ton Manual Chain fall Size Chain falls and air hoist can be obtained from multiple manufactures in sizes up to 100 tons Typically these hoists are not made for material handling but for precision lifting as the speeds that they reel in and out are quite slow at only a few feet per minute The weight of the chain fall itself can be considerable and the weight per length of the chain must not be forgotten as the amount of chain can be varied to accommodate different lift length Air hoists require air pressure to operate and without suitable air pressure will not engage for lifting or lowering Popular heavy lift air hoists made by J D Neuhaus requi
64. el block can be considered if it is critical that no torsion be transmitted to the attachments however for most critical lifts this is not a concern One must be careful when adding a swivel because some wire ropes cannot be allowed to twist as they are loaded Due to the factors mentioned above the modulus of elasticity of a wire rope will vary considerably during its life generally increasing throughout The greatest portion of the structural stretch occurs during the initial period of its life Below is a table of commonly used approximate values for modulus of elasticity for various constructions It can be seen that an Internal Wire Rope Core IWRC increases the stiffness of the rope The values shown below are for wire ropes that are broken in and constructional stretch removed Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 20 of 108 Rope Classification Zero through 20 Loading 21 to 65 Loading 6 x 7 with fiber core 11 700 000 13 000 000 6 x 19 with fiber core 10 800 000 12 000 000 6 x 36 with fiber core 9 900 000 11 000 000 8 x 19 with fiber core 8 100 000 9 000 000 6x 19 with IWRC 13 500 000 15 000 000 6 x 36 with IWRC 12 600 000 14 000 000 8 x 19 with IWRC 12 000 000 13 500 000 8 x 36 with IWRC 11 500 000 13 000 000 Applicable to new rope with constructional stretch removed Table 5 Approximate Modulus of Elastici
65. elow gives the working load limits for Crosby Hooks as well as the chain and wire rope dimensions typically used with these smaller hooks amp S 3316 S 331 r 9 S 319 S 320 322 3322B Series Series Series Positioning Only Crosby Hook Identification amp Working Load Limit Chart S 1316A amp S 1317A Only Grade 100 Chain S 316A S 317A S 318A S 326A Wire Rope XIP Grade 80 Chain Mechanical Splice Chain Size Working i i Minimum Load Limit Thread i i Size i in 6 2500 5 16 2000 1 2 13 UNC 7 1 4 5 16 7 8 4500 7 16 3800 94 5 8 11 UNC 3 8 10 f i 3 4 10 UNC 8 13 1 8 UNC 16 1 1 4 7 UNC 22 26 18 20 28300 1 19700 am mm a __ am 1 2 Ultimate Load is 5 times the Working Load Limit based on XIP Wire Rope Ultimate Load is 4 times the Working Load Limit based on Grade 80 or Grade 100 Chain Working Load Limit The maximum mass of force which the product is authorized to support in general service when the pull is applied in line unless noted otherwise with respect to the centerline of the product This term is used interchangeably with the following terms 1 WLL 2 Rated Load Value 3 SWL 4 Safe Working Load 5 Resultant Safe Working Load Table 16 Hook Working Limits Table reprinted with permission from the CROSBY GROUP Use or disclosure of data contained on this page is subject to the re
66. en erecting units requiring a high degree of control of angle and positional tolerance Large chainfalls as are readily available with working loads of 100 tons but these require considerable time to set up and are generally avoided if possible For small lifts and material handling in restrictive environments these devices still rein supreme as the ability to maneuver loads through sling adjustments is crucial Wire rope has been the material of choice for almost two centuries and replaced chain in almost all rigging applications This material was much stronger and more resilient than fiber rope and cheaper and much lighter than chain slings The development of wire rope stems from the discovery that drawing a wire creates very high tensile strength as this process purifies the steel A wire rope consists of bundles of strands each consisting of several drawn wires which are all wrapped around themselves and therefore transfing load to each other though friction Wire rope remains very popular with riggers since the load bearing components are not only tough but visible allowing quick visual inspections for indications of wear or damage on all external surfaces This toughness along with ease of inspection generates the confidence required for lifting and handling gear Synthetic slings are gaining dominance for high capacity lifts because wire rope and especially chain slings often are heavy or bulky and there are many benefits of keeping the
67. eristics vs other Fibers Slingmax Technical Bulletin 23 Oct 2004 TB23 Abrasion amp Cut Protection for Synthetic slings Slingmax Technical Bulletin 27 HPF Cordage Vs Twin Path Extra Slings Slingmax Technical Bulletin 29 Jun 1999 Twin Path Cleaning Program Test Results Slingmax Technical Bulletin 30 Jul 2002 Twisting Phenomena Slingmax Technical Bulletin 33 2001 Strength Retention of Used Twin Path Extra Slings Slingmax Technical Bulletin 34 Effect of Cold Temperature on K Spec Core Yarn Slingmax Technical Bulletin 35 Nov 2005 TB35 The Check fast inspection system Slingmax Technical Bulletin 40 Nov 2007 Slingmax Advisory Nuclear Regulatory Commission NRC Regulatory Issue Summary 2005 25 Supplement 1 Clarification of NRC Guidelines for control of heavy loads dated May 29 2007 Slingmax Feb 2010 Testing of 10 inch Covermax Dyneema Sleeve 02 01 2010 Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 107 of 108 New Composite yarn Developed for Slingmax TPXC Twin Path Extra Slings Wire Rope News amp Sling Technology August 2002 Skookum 2003 General Catalog Sk 02 10 Hubbard Oregon Tiger Brand Wire Rope Engineering Handbook United States Steel Company Pittsburgh Pennsylvania U S Department of Energy 2004 DOE Standard Hoisting and Rigging DOE STD 1090 2004 Washington D C Valero Krotz Springs 2002 Critical Lift Guidel
68. es Engineering Command document relates to the management of weight handling equipment for the US NAVY This publication covers a variety of rigging activities from cranes to miscellaneous rigging equipment Section 14 provides recommendations for rigging gear such as slings hardware scales and load cells and subpart 14 7 4 3 specifically covers roundslings Specific topics in this short subpart relate to the inspection rejection repairs and use criteria of synthetic roundslings The guidance pertaining to slings mainly references ASME B30 9 criteria with some exceptions A rigging engineer or lift designer reviewing this standard might be most interested in specific comments in this chapter on specific limits for roundsling use A brief synopses of some of these important points in the standard are States that roundslings shall only be used in the lifting applications for which they were designed by the original equipment manufacturer Strict compliance with OEM s instructions are required Recommends split pipe or other rounded shoes hard material to protect synthetic slings from sharp corners or edges Warns users of arrangements that bunch slings in the bowl of shackles as they can cause uneven loading on the fibers of the sling Table 14 4 indicates reductions for choker hitches for synthetic web and roundslings which is slightly more conservative than most tables This table has a much lower allowed rating than often found in other ta
69. es ails ings ry ala Over Over O 1010 184 requires all eli 000 538 exposed to temperatures over 1000 F to posed to tem l r over be removed ftom servos ba raned from e peara n Table 14 Temperature based Chain Rating Figure reprinted with permission from the CROSBY GROUP When designing lifts attention has to be paid to how the chain wraps around the corners and pads should be used when chain is in contact with sharp corners This is shown in Figure 19 below WRONG RADIUS RIGHT 50 REDUCTION PAD CORNERS 2x CHAIN DIAMETER Figure 26 Corners and Chain Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 63 of 108 Chain is one of the stiffest sling materials when used in the vertical direction At angles other than vertical the weight of the chain becomes an important factor as catenary factors allow the chain to apparently lengthen as the load increases As these translations and deflection are significantly larger that the ductility of steel they will therefore govern the elongation and can be relatively tricky to figure out as the effects are non linear End Connections Chain has the benefit that one can easily vary the length of the sling by moving the attachment one link down the chain Several companies make attachments that a link can be dropped trough securing a connection Usually chain slings are manufactured with hooks and maste
70. even more aware of potential and unexpected problems that these new materials may bring Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 34 of 108 Manufactures The entry barrier into high performance synthetic sling manufacturing is significantly higher than other sling materials which has resulted in fewer manufactures making them and fewer different high performance fiber products available The development of new fibers is a significantly research intensive and expensive endeavor which prevents most from undertaking this activity The primary maker of high performance synthetic slings fibers is Slingmax which in turn licenses manufacturing rights to assemble Twin Path slings worldwide to approximately 22 manufactures in North America Some of these include American rigging Bairstow Bishops lifting Carpenter group I and I sling J Henry Holland Lift it Rasmussenco Slingset Safety Sling Yarbrough and many others The umbrella of Slingmax originally stems from an agreement with DuPont to be the sole distributer of the K Spec fiber used in Twin Path slings although this is no longer the case Slingmax ensures that all K Spec fiber slings are made under the same standards meeting the same specifications and being of identical quality All manufacturers of the Twin Path slings submit samples on a yearly basis to ensure that the process is being f
71. f the sling Milking is the process of removing these wrinkles from the bearing area helping to create a smooth uniform bearing surface High shear and bearing pressures are typically associated with sharp corners although will be present on any edge if the sling tension is large enough and the radius small The resultant forces and pressures can abrade or cut into a roundsling cover as well as damage or sever the core strength fibers Bearing pressures may also be related to useful Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 43 of 108 life expectancy but the exact mechanisms which causes this are still in question and no known test have been done specifically design to test this theory All standard organizations indicate that synthetic slings absolutely must be protected from these high bearing or shearing pressures but most do not suggest what the safe limit is with the exception of the Web Sling and Tie Down Association WSTDA which has a comprehensive standard for polyester roundslings Lift it a Los Angeles manufacturer of Twin Path slings has recommended applying the WSTDA standards for polyester roundslings to those made of high performance fibers such as Twin Path slings with K Spec cores The WSTDA has perhaps done the most research into bearing pressures on roundslings and they recommend a maximum bearing pressure of 7 000 psi in the
72. f the sling bearing into itself It is very important to note that the capacity of a choker hitch with an endless sling could be less than typically quoted for slings with spliced eye terminations Spliced eye slings have two paths for the load to transfer through in the choking eye effectively halving the sling loading at the termination The WSTDA standard for synthetic roundslings suggests that since an endless sling does not have an extra path at the choking termination the capacity should be further reduced This is different than ASME guidelines which use a standardized linear deduction A table showing the difference between an endless sling and spliced eye sling reduction factors Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 41 of 108 can be seen in Figure 18 The WSTDA table for choking hitch reduction of endless roundslings is based solely on theoretical calculations based on geometric angles and the author is aware of no documented and published testing which may confirm this reduction However Slingmax has stated that this standard reduction is conservative for Twin Path slings It should also be noted that other organizations have slightly different deductions for choking hitches Most of these reduction factors typically reduce the hitch capacity further from the already lower standard choker rating with the exception being NAVFAC P 307 which also
73. form of sling equalizer allowing a more equal tension on all four slings during a single crane lift These plates work because they create what can be considered a soft connection in that they allow rotation that effectively varies the length of the slings by the translation of the attachment points through an arc The use of flounder plates is safer and stronger than other methods of sling equalization such as wrapping the sling over the hook because it prevents slippage of the slings if the arrangement is unstable and furthermore does not create a loss of strength as a result of a bend radius created in the slings over the hook A representation of a typical single crane lift utilizing two flounder plates can be seen in Figure 20 Figure 20 Two Flounder Plates on Either Side of a Sister Hook Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 86 of 108 Flounder plates have certain strength advantages over other methods of sling equalization but attention must still be paid when configuring a rigging arrangement as there are limitations to their effective range It should be realized that the loads in the slings are not always distributed in the ideal 50 50 share but are a variable depending on the geometric factors and sling properties Flounder plates work as the slings attached impart moments that rotate the plate into a stable arrangement in which there is
74. g or rigging judgment accompanied with analytical thought Furthermore a manufacturers should always be contacted to determine what the most current advice is and whether an intended application is within what is considered acceptable practice Twin Path synthetic slings do have disadvantages which are not always highlighted in the manufacturing sales and use literature although to the manufacturers credit the product continues to undergo modifications to improve its safety and reliability Many of these disadvantages relate directly to the soft nature of the material which they are composed of and the fact that the core of these fibers cannot be seen These load carrying fibers are susceptible to being damaged from high bearing pressures or being cut by edges protruding from an object regardless of how sharp the edge is Some roundslings have documented bearing considerations that are generally not encountered with synthetic web slings since web slings by their nature are significantly wider than they are thick which results in lower bearing pressures Since roundslings have a lower cross sectional aspect ratio this generally leads to higher bearing pressures that may need to be considered along with cutting considerations If a wire rope is subjected to large bearing pressures flat spots and subsequently broken wires will usually be readily visible alerting the rigger to the need to replace or repair the sling As a roundslings strength core i
75. gs inside of which no decrease in the rated load is required The Code of Federal Regulations CFR Title 29 Section 1915 is the mandatory regulatory law covering shipyard employment which all compliance must be in accordance with Within this main section Subpart G sections 1915 111 through 1915 120 covers rigging equipment and material handling No paragraph of this section refers to synthetic slings or has any provisions which can be applied to assist the design of a lift The Code of Federal Regulations CFR Title 29 Section 1926 is the mandatory regulatory law covering construction for which compliance for those industries must be in accordance with Since the construction industry is much larger than the shipbuilding industry in the United States most rigging equipment manufacturers comply with and reference this section Also Subpart 1926 30 of the act states that shipbuilding or ship repair that is done under government contract is subject to the construction act 1926 with the exception naval ship construction Within the construction act several Subparts deal with rigging equipment but Subpart H is most applicable as it deals with material handling The main sections within this for slings is 1926 251 which has over twenty tables of rated capacities for slings However no paragraph of this section refers to synthetic slings or has any provisions which can be applied to assist the design of a lift with this material The synthetic
76. gs is to spread the load out over the lifted unit such that the forces are not concentrated in just a few areas This method requires padeyes or special lifting points to be installed onto the structure to which a shackle is attached The attachment of the sling to the shackle or any metal connection must be chosen with consideration for bunching and bearing pressure Bunching of the sling is a problem resulting from the use of an undersized shackle or connection without enough width for Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 42 of 108 the sling to spread out on and results in uneven loading and reduction of contact surface between the shackle and the sling An example of bunching can be seen in Figure 19 Severe bunching of a sling can result in reduced capacity and permanent damage to a sling The use of a sling without significant room may also result in the pinching of the fibers at the edges which can cause cutting and permanent damage Slingmax sells shackle pin pads which protect the sling form the sharp corners near the shackle pins edge or threads of the pin These are intended to be used with high performance Twin Path slings and help provide a softer and larger bearing area FOLDING BUNCHING OR PINCHING OF SYNTHETIC SLINGS WHICH OCCURS WHEN USED WITH SHACKLES HOOKS OR OTHER APPLICATION WILL REDUCE THE RATED LOAD E 5 p
77. hipyard specific as many shipyards have there own designs that have been designed and built in house This familiarity helps guide the rigging engineering design process as the potential limits are better understood There are however consultant engineering firms that can design and engineer padeye A typical padeye will have circular boss plates on both sides surrounding the shackle pin hole These plates perform several critical functions Many documented steel single plate padeye failures are due to shear in this highly stressed region and there are well documented standards and guidelines for stresses due to bearing forces tensile forces near the shackle hole splitting and fracture of the surface beyond the hole and shearing or tearing near the edges of the hole These well documented modes of failure result in well defined requirements and a similarity among most padeyes surrounding the pin connection hole The exception being aluminum padeyes that may or may not have brass or bronze inserts pressed inside of the shackle hole to provide a harder bearing surface There is significant variance in the lower half of many padeye that reflects individual designer choices as well as load requirements based on particular design criteria Some padeyes are designed with ample space beneath the shackle hole such that the padeye can be trimmed off and reused multiple times Also some padeyes have chocks or gusset plates to help stabilize the weak axis of
78. iderations one should be familiar with when selecting a wire rope includes e Classification e Strength of individual strand e Fiber core or internal wire rope core e Lay of wire in rope e Rotation resistance e Fatigue resistance e Bearing strength e Design factor required e Sheave or shackle diameter intended e Compacted wire rope e Plastic filled or coated e Corrosion resistance Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 18 of 108 As significant data has been compiled about wire rope libraries of failed wire ropes have been photographed compiled and tables produced cataloging the resulting failure modes that one should be familiar with Typical modes of failure for wire rope are well documented and include e Ropes of incorrect size construction or grade e Ropes allowed to drag over obstacles e Ropes operating over sheaves or drums of to small a diameter e Ropes overwinding or crosswinding on drums e Ropes operating on sheaves or drums that are out of alignment or improver fitting grooves and broken flanges e Ropes permitted to jump sheaves e Ropes subject to moisture or acid fumes e Ropes permitted to untwist e Ropes subjected to excessive heat e Ropes kinked e Ropes allowed to accumulate grit producing internal wear Measured Length As the length of slings can be critical to keeping a lift level or ha
79. ie Down Associations WSTDA A rigging engineer or lift designer reviewing this standard might be most interested in specific comments in this chapter on specific limits for roundsling use A brief synopses of some of these important points in the standard are Sets a minimum roundsling design factor of five which is the ratio of minimum breaking strength to rated load The chapter on roundslings is mainly oriented towards polyester yarns and indicates that for roundslings of other yarns one should check recommendations of the manufacturer Indicates that polyester roundslings have a temperature range of 40 F to 194 F and that some other synthetic roundsling materials do not retain its published breaking strength above 140 F Suggests that users of roundslings made from other materials should consult the manufacturer for safe temperature ranges This chapter indicates that synthetic roundslings should not be used to support personnel platforms The section on choker hitches uses the standard reduction typically associated with spliced eyes and does not include any extra reduction due to the fact that the choking portion of the sling may be under greater load as seen in the WSTDA standard This chapter sais nothing of maximum allowable bearing pressures except that slings must be protected against cutting It states that many of the rated loads to be referenced are based on pin diameters are from the WSTDA standard for synthetic polyes
80. ine Louisiana Wire Rope Technical Board 2005 Wire Rope User Manual 4th ed Stevensville MD Wire Rope Technical Board 2007 Wire Rope Sling User Manual 3rf ed Stevensville MD WSTDA RS 1 2001 Synthetic Polyester Roundslings Web Sling And Tie Down Association WSTDA RS 1 2010 Synthetic Polyester Roundslings Web Sling And Tie Down Association Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 108 of 108
81. ing Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 48 of 108 Wear Protection ASME considers cut protection mandatory where synthetic slings make contact with edges as cutting is the number one cause of synthetic sling failure Wear and abrasion protection can also help prolong a slings life Many products are sold for synthetic slings with the specific intent to minimize bearing pressures and reduce the chance of cutting or abrasion Most of the edge protectors sold are based around the concept of softening the surface on which the sling bears and increasing the bearing area to reduce the pressures present Some wear protection is sling oriented being sewn or attached onto the sling at a designated bearing area and other protection is intended for the areas of contact Load oriented protection is typically intended to be used for basket and choker lifts when the corners of the load may need specific softening Consideration for the specific protection chosen for a given application is necessary since different protectors have different temperature and strength ratings There are several products available that attach to the sling or load and protects against failure due to abrasive surfaces cutting or bearing problems e Dyneema bearing sleeves are typically sewn into designated bearing spots on a Twin Path sling and are intended to provide protecti
82. ir standard for roundslings with a polyester core This recommendation is based on an unreleased data set stemming from destructive tests conducted on 375 single path polyester roundslings According to WSTDA these slings consistently broke at approximately 28 ksi of bearing pressure with failure modes being a combination of shear and tension The 7 000 psi bearing limit was then set with the desire to maintain approximately a design factor of 4 between a fully tensioned brand new sling and the perceived bearing failure limit These results may be applicable to low denier fibers similar to polyester but any extrapolation of these results to higher capacity yarns is yet uncorrelated Also failure modes of roundslings may be affected by the amount of elongation that the core yarns undergo elastic slings with polyester cores may behave very differently than relatively rigid slings with K Spec cores Slingmax states that the maximum safe bearing pressure for K Spec Twin Path Extra slings is 25 000 pound per inch of width or 25 ksi on the projected bearing area Slingmax conducted a cutting and bearing pressure test in early 2010 where a 300 000 rated sling was loaded to capacity around a sharpened steel plate The intent of this test was to prove the suitability of TPXC slings that have Dyneema bearing sleeves on the cover This cover is intended to increase safety and life expectancy of a sling through minimizing the chance that bearing pressures wil
83. ively heavier with more consideration given to the structural design Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 75 of 108 SlingLength 6 2xL L D 5 70 24 SlingLength 6 2xL L D 5 70 Difference of Sling Length Difference of Sling Length in 10 00 7 503 5 00 2 503 0 00 250 5 00 7 50 10 00 TE ee a E a E EF O o ca 2 45 45 DB 3 75xL DB 3 75xL DB 2 5xL DB 2 5xL DB 1 25xL DB 1 25xL 3 3 z R 75 75 80 80 85 85 Slinglength 11 2xL L D 5 70 SlingLength 11 2xL L D 5 70 Difference of Sling Length Difference of Sling Length in 10 00 7 50 5 00 2 50 0 00 2 50 5 0056 7 50 10 00 14 12 10 3 6 4 2 o 2 4 6 8 10 12 14 45 45 DB 3 75xL DB 3 75xL DB 2 5xL e DB 2 5xL DB 1 25xL DB 1 25xL u u Q 65 Q 70 Gd 75 75 89 89 85 85 SlingLength 21 2xL L D 5 70 SlingLength 21 2xL L D 5 70 Difference of Sling Length Difference of Sling Length in 10 00 7 50 5 00 2 50 0 00 2 50 5 00 7 50 10 00 14 12 10 3 6 4 2 o 2 4 6 8 10 12 14 45 45 DB 3 75x
84. king loads for common rigging items such as shackles and rings that can be found in OSHA federal standards under safety and health regulations for general construction Part 1926 These requirements are followed by US manufacturers and it is common rigging practice to use ratings developed by US manufacturers The OSHA Part 1915 specifically pertaining to shipyards has significantly less information on rigging hardware and their requirements but most shackles for rigging will exceed or conform to Part 1926 and the requirements there in The code of federal regulations title 29 part 1926 251 deals with rigging equipment for material handling and subpart f deals specifically with shackles It states as follows 1 Table H 19 shall be used to determine the safe working loads of various sizes of shackles except that higher safe working loads are permissible when recommended by the manufacturer for specific identifiable products provided that a safety factor of not less than 5 is maintained Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 14 of 108 TABLE H 19 SAFE WORKING LOADS FOR SHACKLES In tons of 2 000 pounds ae Pin diame Safe work Material size inches ter inches ing load Table 4 Shackle Safe Working Loads OSHA 1 4 2 2 3 2 4 3 5 6 6 7 8 2 10 0 11 9 16 2 21 2 Modern manufacturers shackles will typically exceed
85. l cause cutting of the core fibers During this test an estimated bearing pressure of over 37 500 psi was achieved and an inspection afterward revealed no indications of any damage or abrasion being present on the Dyneema sleeve or the bulked Nylon Cornermax cover This bearing pressure exceeded the official rated pressure for the Dyneema sleeves by 150 which is rated at 25 000 psi Full details of this test can be seen in the Slingmax report entitled Testing of 10 inch Cornermax Dyneema Sleeve Since the bearing pressure on the core fibers is also a direct function of the bending radius and the Dyneema sleeve only marginal added extra area it would be logical to conclude that the bearing pressure on the core fibers during this test was almost equally as large This shows that excessive bearing pressure on Twin Path slings does not necessarily result in an instantaneous failure of the sling Large bearing pressures may however reduce the lifespan of a sling but the exact function or rate of which this degradation happens is unknown To maximize sling life it is sometimes recommended that the bearing points be rotated along the slings length to avoid continuously loading the same area It is believed that continuous bearing pressures in the same area can harden the core fibers as evidenced by Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 44 of
86. ling down to the load If the bow of a shackle is allowed to hang from the sling during this process there is a better chance that both sides will be of equal length minimizing the chance of tears in the cover from rendering Additionally although not visually apparent there should be some tendency for rendering of the internal core fibers of a roundsling as they naturally adjust themselves into a position that uniformly shares the load between them Internal rendering will occur immediately after manufacture as the slings internal core fibers adjust themselves to a more optimal position This process may also occur to some extent when the diameter of a slings bearing point is changed such that the ratio of the circumferences for the inside path core fibers and outside path is slightly altered During any rendering of internal core fibers some of the loaded core fibers may bear into the others preventing them from freely adjusting and considerable frictional and abrasive stresses may develop For these reasons it is may be advisable that relatively consistent connection hardware be maintained to minimize any internal rendering effects and thus maximize life expectancy of a sling IO e TERE Min Ve ERO PS SPS Eee a RES SS Da td ee I in rl GO IN rl GFT RR NF EEE EE E A LEER A AEN DE Tt ae i OT en ae er nos zA INNER CORE FIBERS OUTTER CORE FIBERS Figure 22 Cover Inner and Outer Core Fibers of a Roundsl
87. lity environmental temperature fittings inspection removal repairs and operating practices A rigging engineer or lift designer reviewing this standard might be most interested in specific comments in this chapter on specific limits for roundsling use A brief synopses of some of these important points in the standard are Sets a minimum synthetic roundsling design factor of five which is the ratio of minimum breaking strength to rated load Defines two main groups of roundslings those made of high capacity fiber and standards capacity fiber This definition effectively rates the strength of the fiber with high capacity fiber defined as those above 15 grams per denier and standard core material being less than that Indicates that the load bearing yarns of polyester roundslings be used at temperatures between 40 F to 194 F This standard covers the three standard rigging hitches but does not present a table for the reduction of rating for a choker hitch due to choking angle States that roundslings in general should not used at temperatures above 180 F and that High Molecular Poly Ethylene HMPE cores such as Spectra or Dyneema should not be exposed to temperatures over 158 F This standards does not specifically address bearing pressures of roundslings but does indicate edges and abrasive surfaces should be kept from contact with sling The section on fittings states that fittings must be smooth and be wide enough to prevent
88. long life expectancy of slings seems plausible especially since synthetic slings are not subject to corrosion like wire rope However it needs to be noted that these performance tests are done under laboratory conditions and will never perfectly reflect real world circumstances 44 6 Z d Z d d d aA 4 d B C D E Figure 21 End Connections for Vertical Hitches Figure 21 shows end connections common to vertical hitches with endless roundslings The best type of termination is a right angle connection with the sling normal to the axis of curvature of the attachment where the bearing pressures are low such as when a sling is wrapped around a large diameter pin as shown in case A of Figure 21 The surface finish of the pin that the synthetic roundsling is bearing on should be smooth with no gouges that can damage the sling during rendering or potentially tear the sling Case C and D of Figure 21 are very similar to the cyclic tests conducted in Slingmax technical bulletin nine Although both terminations are considered safe if the rating of the pin or shackle is above that of the sling after tens of thousands of loading cycles the sling in case D may be more likely to show signs of wear and age This is mainly due to the two degree of
89. many plys a sling can have When a critical lift requires a large capacity synthetic sling typically a round sling is used Roundslings can be characterized by having a protective cover around the strength yarns which are not woven together but loose inside and transfer the load evenly between them through friction and rendering There are two main materials for the strength elements of roundslings polyester and K Spec with the latter being the highest capacity synthetic sling commercially available This K Spec round sling is commonly referred to as a Twin Path Extra with Covermax TPXC and have proven themselves to be reliable and forgiving and become one of the most prominently used roundslings at shipyards The WSTDA has a standard for polyester roundslings which is fairly comprehensive but the TPXC slings currently do not have and extensive standard covering their use The follow section aims to fulfill this need for more guidance on their safe use and included the prospective of and end user Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 32 of 108 Twin Path Extra Synthetic Slings Twin Path Slingmax Sparkeaters K Spec Covermax are registered trademarks of Slingmax One drawback with the shift to newer high capacity synthetic slings is that the reference documents and standards that sound engineering requires is relatively sparse when c
90. mensional lift further complicates rigging analysis as one would now have to account for the torsional resistance and deflection in the block As any real world situation will have not just one sling longer but multiple tolerances stiffness s and variations to deal with one can imagine the complications for analysis that will result Inevitably to a significant degree a rigging engineer or lift designer is going to have to strive to implement the best possible arrangement with the best equipment obtainable and then select appropriately increased design factors and margins to account for the range of variability that exists within or because equipment as well as operational factors and other unknowns A rigging Engineer can review typical tolerances for slings and installation variances and get a rough approximation of the amount of load sharing that can typically be expected POOR EQUALIZATION BETTER EQUALIZATION RESULTING FROM SLING LENGTH DIFFERENCES RESULTING FROM SLING LENGTH DIFFERENCES FAR LEFT SLING MADE 2 LONGER FAR LEFT SLING MADE 2 LONGER Figure 14 Best Type of Equalizer Under Spreader Beam Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 81 of 108 Another important aspect of rigging arrangement design is that the designer must account for the fact that during some rigging operations the arrangement configuration will chang
91. metimes when fittings at either end of the sling are at 90 degree angles to each other it is required that the sling be twisted through this arc over the course of its length This practice is believed to be completely acceptable Slingmax did experiments which are documented in their technical bulletin 30 which shows that some twisting of the slings actually increased their strength up to a certain point The tests were performed on six 5 ton slings five feet in length and this limited data sample suggested that twisting up to perhaps one twist per every 5 widths in length increased the slings strength This increase in strength is believed to be due to the internal adjustments that twisting allows such that a better more even load distribution is facilitated among all core fibers in the bundle Importantly it should be noted that these tests were done on slings of relatively small width and that larger higher capacity slings that are wider may not have the exact same relationship between twisting and strength These experiments do show however that slight twisting of slings as shown in Figure 16 is most probably not harmful Figure 16 90 Degree Twisting of Twin Path Sling Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 40 of 108 End Connections Synthetic sling connections are different than tradition
92. n Table 3 Recommended Shackle Size for Wire Rope Sizes OROSHA This table provides useful information given certain assumptions that may not always be listed or easily identifiable This particular table should be used with caution as wire ropes and shackles can vary in strength depending on the specific manufacture and construction Furthermore this table makes no allowance for termination type of the wire rope which will reduce its strength unless a socket connection is used This is a good example that one should Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 13 of 108 exhibit caution when referencing tables and always apply good Engineering judgment over all references and components in a given rigging arrangement SHACKLES METAL SPAR Ssmcsiess GUYLINE SAFETY STRAPS 22 The minimum size of shackles required for joining or attaching lines are shown in Table 7 5 Table 7 5 Bell Shaped and Sleeve Shackles Used to Join or Attach Lines Shackle Size In Inches 114 138 11 2 15 8 2 23 The minimum size of flush pin straight sided shackles for joining or attaching skyline extensions are shown in Table 7 6 Table 7 6 Flush Pin Straight Sided Shackles Used for Attaching Skyline Extensions Table 3 Recommended Shackle Size for Wire Rope Sizes OROSHA Standards and Regulations There are well defined requirements and safe wor
93. n the slings when there is a difference in length between them which is shown on the horizontal axis of the curves In most of these tabulated graphs this length difference is shown as percentage of sling length to keep the curves in a non dimensional format Figure 9 shows these curves in two formats where on the left is sling deviation as a percentage of sling length and on the right is in inches of deviation The graphs presented here show increasing sling length down the page depicting 10 foot 20 foot and 40 foot sling lengths with additional length added to account for 85 ton Crosby shackle on each end When the slings have exact equal lengths there is a even load share with 50 of the total load in each sling It can be seen on the right side of this figure that a high aspect ratio equalizer shares the load remarkably well Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 74 of 108 with the more heavily loaded sling having 55 of the total load resulting from a 4 inch difference in sling length The left of this figure shows what appears to be less of a load share but this is slightly deceptive because this information is presented in terms of percentage of sling length and a set percentage of a longer sling represents more deviation from an ideal share Figure 10 is a direct comparison of a high aspect ratio short length equalizer with a low aspect ratio
94. ngth and angular arrangement of the slings Overall sling leg length can vary from several factors such as manufacturing tolerance of the sling height variation in the location of the attachment point and differences in the size of shackles used The load in a given sling can be a variable that is impossible to calculate and often can only be estimated once the lift has occurred through inferred measurement This is especially important when both legs of the sling are near vertical as seen in Figure 1 and Figure 2 where a rotation and load shift will result from one sling being longer than another Experienced riggers will usually visually note the rotation when load is first taken up and then add different size shackles as required to both slings to attempt to even out the load Typically a correctly rated shackle will be added to the longer side and a larger overrated shackle will be added to the shorter side which will tend to even out the load distribution by bringing the overall lengths of the slings closer to uniformity 4 x N i J b Ca J i Mm Mm RA S S PA S4 M O O a a Figure 2 Depiction of Flounder Rotation Resulting From Sling Length Variance When designing a rigging arrangement with flounder plates care must be taken to ensure the arrangement is balanced Initially the line of action of the two resultan
95. nmeaguattevstontaaaviecsemessaasss 102 Figure 36 Ways of Loading HOOKS xcssccstercpcessaceesteancasendeeneoeaerepleeeaseeyeeeeae 102 Figure 37 Whirly Mobile Cranes at NASSCO ssseessesssssesressrseresrrssrserssressreeresrenseseees 104 Figure 38 Typical Crawler ane sasossseiisciinrsisosii inasai aR ateisi tos 105 Tables Table 1 Side Loading Load Reduction sic tasccssespansorasedgestacnsasededsadastasdaaseaastaaeecacdassoeecussenens 12 Tabl e 2 Typical Crosby Sha kles 2sscidvexsacadenceatemstaaastevseunreswsdteasoassuantendstassasunuunedveniasets 13 Table 3 Recommended Shackle Size for Wire Rope Sizes OROSHA eee 14 Table 4 Shackle Safe Working Loads OSHA ecceeesceeesceeceeececeeeeeceseeeceneeeseteeeesaeees 15 Table 5 Approximate Modulus of Elasticity for Wire Rope in psi 21 Table 6 Terminal Efficiencies Approximate occcisccccccececceeessieccsesacidesedasdevesieedecesuiivenena 23 Table 7 OSHA 1926 251 Tables H 3 to H 4 ciicssscunceas cadesacstivecacesceanizavtanaap cxgeseneneencradke 27 Table 8 OSHA 1926 251 Tables H 5 and FG ise sessctecssvesceceatoed aces vedesetast necssvndeecseseecensas 28 Table 9 OSHA 1926 251 Tables H 7 and eS iysceoicacccnsecsnosanesiendssetansnicisioesaaeemyencstetenes 29 Table 10 OSHA 1926 251 Tables TAO cess csctarvantdunsasusdeaouteunnwagiidetanuddadasesddesstnetevasmagiadstanye 30 Table 11 OSHA 1926 251 Tables H 9 to H 10 sessesesessrsessssessrrsrerrersrrsrrsrersrssesrresee 30 T
96. ntained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 91 of 108 The concepts addressed when reviewing flounder plates are also directly applicable to lifts with spreader beams Spreader beams can be thought of as very large flounder plates as shown on the right of Figure 26 As rigging slings are relatively rigid the top half of a spreader beam arrangement will have very similar behavior that a large flounder plate made from steel plate In this regard a lower aspect ratio arrangement will result in less angular deflection of the load for a given of center of gravity offset TYPICAL FLOUNDER TYPICAL SPREADER PLATE ARRANGEMENT BEAM ARRANGEMENT Figure 26 Comparison of Flounder Plate and Spreader Beam Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 92 of 108 6 SPREADER BEAMS Manufactures Typical shipyards will require spread lifting capabilities matching the lifting capacity of their largest crane or a rough average of about 300 tons This capacity is larger than most commercially available bar manufactures produce and can require a custom order or design Readily available commercial spreader bars have primarily smaller lifting capabilities than but larger working loads can be obtained Spreader beam manufactures include Bushman Cadwell Modulift Tandemloc Inc
97. ollowed and all slings meets the quality standards General Construction Twin Path roundslings with K Spec load bearing fibers follow the same construction methodology as other roundslings The initial step of roundsling constructions starts with a toroidal protective cover that the load bearing fibers are wound within The protective cover may be composed of multiple layers of different materials and is intended to prevent physical containments and Ultra Violet UV light from interacting with the core fibers where they will have detrimental effects Single path roundslings have a single toroidal cover in which the load bearing fibers are wound multiple path roundslings are either composed of multiple toroidal covers sewn together or a single large toroidal cover sewn down the middle to partition the cover into two sections Making a cover with two toroids sewn together has traditionally resulted in a tighter cover with less bagginess and wrinkles which sometimes snag on terminations However the manufacturing processes for this arrangement may allow the core to be perforated with a needle and thread so this has resulted in more recent configuration of having a single cover separated into two paths with sewing down the middle For Twin Path slings this outside cover is typically made of green bulked Nylon with a layer of red underneath to help ease the inspection for sling tears and is referred to as Covermax Dyneema sleeve pads can also be added
98. ompared to wire rope which has a century s worth of collective use history and data available For the K Spec multiple cored slings no standard organization had produced documentation with regard to their proper use although different individual manufacturers of the product have created information to meet this need This catalog attempts to compile the information of different manufactures of these various slings in an organized format combined with the use perspective of an end user This shipyard rigging equipment catalog attempts to present much of the information that is known or suspected with the goal of helping to increase the safe adoption of this cost saving gear As this technology is still in its infancy much of the documentation on these slings does not have significant data recorded through scientific experiments conducted by multiple third parties and standard organizations Where information is suspected but cannot be confirmed or necessarily proven this guide uses terminology such as it is suspected or it is believed The promotion of information that cannot be proven as fact is seen as beneficial as it is intended to promote collective thought with regards to the use and failures observed with these slings to increase the collective knowledge available This document is intended to provide a foundation of information available for proper Twin Path sling use but it is no substitute for the application of sound Engineerin
99. on from abrasion and cut resistance e Mesh Guard protectors which have a unique combination of wire mesh and felt cloth designed to protect a sling from a sharp corner e Magnetic corner protectors are made which are effectively three quarters of a cylinder plastic castings which are designed to create a radius to soften the edge of a load These devices do however have their own maximum allowable bearing pressure along with temperature considerations e Shackle Pin Pads are designed to be inserted onto a shackle pin to prevent the cutting or binding that may occur on threads that are not fully engaged or the sharp interior corner e CornerMax cut protection pads are made of multiple plastic rods enclosed in tough padding which is designed to fully enclose the edge load and minimize cutting potential These pads are typically attached to the sling with Velcro to minimize the chance they will slip out or shift during the rigging operation All of these devices have maximum rated loads and maximum widths which can be safely accommodated Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 49 of 108 Figure 23 Dyneema bearing sleeve Inspection and Safety Features The manufactures of Twin Path s slings are always striving to improve their product increase its safety and add features which will allow better inspection to increase reliability and user
100. or flounders will always distribute the load equally is incorrect and even with these devices slings could have zero or minimal tension with the subsequent shifting of load to the others members an understanding of their operational limits is fundamental for safe rigging An example of an improperly designed rigging arrangement can be seen in Figure 13 where it can clearly be shown that the forces acting on the equalizer plates are not depicted in equilibrium on the left The subsequent lifting would result in the rotation of the equalizer plates and in this particular case with a low aspect ratio load sharing device and a non symmetrical arrangement the outside two slings will be relieved completely of any load In the previous section it is shown that low aspect ratio equalizers as shown below are not the best shape to assist the even sharing of the sling forces This zero tension scenario is certainly true if the block is rigid and the slings are stiff However if the block is extremely flexible it would deform and deflect until the outside slings began to see some load Similarly if the slings are very flexible the heavily loaded slings would stretch and lengthen which could also result in the outside slings reengaging themselves and taking some of the load of the block Although both of these factors can be true to some extent typical large ship blocks are not flexible enough and high capacity slings not elastic enough to allow the even distri
101. ost common cover material There are two main reasons for the variation in length of a Nylon cover water absorption and re crystallization Water absorption will make nylon fibers swell and elongate as well as make them weaker in strength Although this can make the cover baggier and more susceptible to abrasion damage it will not affect the overall length Nylons are semi crystalline polymers meaning that they have regions of densely packed high order crystalline structures and amorphous regions of lower order The process of creating a drawing a nylon fiber to create rope or webbing results in a high degree of chain extensions of the crystalline material to create a high strength and higher modulus material However over time the fiber material can have a tendency to shrink through a process of re crystallization This results in a reduction of length of the nylon cover webbing This effect is most commonly noticeable on older slings that have been patched or repaired frequently during their life and the affect is estimated to be up to the order of five percent of total length To overcome this cover phenomenon any accurate measurement of the slings length should be taken when it is loaded to 10 of its rated load In this way one can be assured that the length measurement taken is of the core bundle A slight variation of the measured length of the sling will also result if different size pins are used for preloading the sling for measurement To s
102. page of this document GENERAL DYNAMICS Page 93 of 108 Allowable Loads As large spreader beams are typically unique they will have specific allowable loads associated with them It is recommended that for any given spreader beam documentation be created that explains what these allowable loads are An abbreviated example of such a guide is shown in Figure 28 where allowable loads at specific location can be referenced CONFIGURATION I 60 0004 60 000 CONFIGURATION II 13 i 100 000 100 000 CONFIGURATION III 15 90 000 90 0004 CONFIGURATION IV 14 6 70 000 70 000 70 000 CONFIGURATION V CONFIGURATION VII 6 70 000 70 000 CONFIGURATION VI 6 66 0008 66 000 66 0004 66 0008 66 0008 CONFIGURATION VIII le le 100 000 100 000 Figure 28 Typical Spreader Beam Allowable Load Guidance Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 94 of 108 Sizes and Standard Types Box Spreader Beam NASSCO spreader bars include four adjustable box beams two with 295 ton lift capability and two with 170 ton capability The 295 ton spreader bars have top and bottom lifting attachment which always travel together and span 14 feet to 50 feet with 5 configurations in between These beams however cannot be used as equalizers and are not deigned to withstand much internal moment
103. r links permanently fixed on either end of the chain Standards and Regulations OSHA Standards for Chain Table 15 gives rated capacity in pounds for alloy steel chain slings based on chain diameter number of sling branches and sling angles Alloy steel has to have permanently affixed durable identification including size grade rated capacity and sling manufacturer Hooks rings and other attachments used with alloy steel chain need to have rated capacity of greater then the alloy chain steel In OSHA s H 2 table they provide allowable wear of the chains job hooks and links TABLE H 1 RATED CAPACITY WORKING LOAD LIMIT FOR ALLOY STEEL CHAIN SLINGS 1 Rated Capacity Working Load Limit Pounds Horizontal angles shown in parentheses 2 Singe Double sling vertical angle 1 Triple and quadn uple sling vertical angle 1 branch Chain size inches sin d E 30 je load ng 60 30 3 250 5 560 3 250 8 400 4 900 6 600 11 400 30 6 600 17 000 9 900 11 250 19 500 15 11 250 29 000 24 000 17 000 16 500 28 500 23 16 500 43 000 35 000 24 500 23 000 39 800 32 50 23 000 59 500 I 34 500 28 750 49 800 60 28 750 74 500 61 000 43 000 38 750 67 100 54 80 38 750 101 000 82 000 58 000 44 500 77 000 63 00 44 500 115 500 94 500 66 500 57 500 99 500 57 500 149 000 12 86 000 67 000 116 000 67 000 174 000 141 100 500 80 000 138 000 112 50 80 000 207 000 1 119 500 100 000 172 000 140 000
104. r equipment such as high performance synthetic roundslings for which a specific national consensus has not matured is not included in the original standard As the ASME sling standard has evolved and been modified with time OSHA has taken the standpoint that full compliance with the current ASME standard is acceptable in lieu of the older guidance incorporated directly into the CFR This policy is quoted as de minimis violations which literally means of minimal violations and basically assumed that there is no indication that newer standards are less safe than what was promulgated in the early nineteen seventies and that most changes are minor An example of this deferment can be seen in a letter on interpretation from 1994 the director of the office of construction suggests that high capacity synthetic slings made from materials like Spectra should have a factor of safety of 6 as this is similar to OSHA s rigging standards for other synthetic fibers This letter also suggest that polyester rope slings maintain a factor of safety of nine However currently OSHA s website seems to indicate that polyester roundslings which are composed of polyester cords should comply with tables identical to those listed in ASME s B30 9 sling standard which is based on a design factor of five This seems to suggests that as standard organizations specifically ASME update their standards OSHA will default to their new recommendations Similarly the
105. re 17 shows this analogy by comparing the similarities between a large gantry crane rigging arrangement and a more traditional use of large equalizers with two cranes In this example both are depicted lifting a small but heavy object that is beyond the capacity of a single crane or winch unit Figure 17 Large Equalizer Beam Between Two Cranes or Gantry Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 83 of 108 A representation of a nested equalizing bar usually present on large gantry cranes is shown in Figure 18 It can be seen that it acts as a cascading group of equalizers which helps distribute the load on the various slings Through independent rotation between the three various members the loads are more or less evenly distributed on all slings Each equalizing member has an infinite aspect ratio which allows an almost completely equal division of the load Complete equalization can only be obtained through the slings having equal and opposite lines of action on each side simultaneously for complete balance to be achieved Unless all slings are vertical this will most likely never be achieved but the design does create the most uniformly equal distribution of load practically possible Figure 18 Typical Nested Equalizer Bar Under Large Gantry Winch House Use or disclosure of data contained on this page is subject to the restriction on the
106. re at least 80 psi of air pressure with flow rates of up to 425 cubit feet per minute for a 100 ton hoist These require considerable hose sizes that must be available at both locations of the lift and erection For this reason manually operated chain hoists have benefit End Connections Typically large chain falls used in a rigging arrangements used for large lifts have standard hooks at the top and bottom These hooks can be used for both connecting to slings or shackles and allow that particular sling leg to be varied in length Standards and Regulations The Occupational Safety and Health Administration has a specific section for the use of chain fall at shipyards which can be found in 29 CFR 1915 114 This section covers regulations for properly labeling chain falls regular inspection and required the mounting structure to be adequate to load and secure the hook from coming loose Other standards that relate to the design of chain falls and airhosts include ASME B30 16 which covers air powered and manual overhead hoists ASME also has performance standards for hoists for evaluating the performance of particular hoists HST 5M Performance Standard for Air Chain Hoists HST 4M Performance Standard for Overhead Electric Wire Rope Hoists and HST 6M Performance Standard for Air Wire Rope Hoists Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 67 of 108
107. rength characteristics that are assumed from these tables based on the five times breaking strength requirement Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 26 of 108 OSHA Table H 3 and Table H 4 gives capacity ratings in short tons for two classification types of steel rope one with fiber core and the other one with independent wire rope core Three different arrangements are calculated vertical leg looped as a basket and choker The tables give the capacities based on minimum bend radius requirements specific termination types and their rated efficiencies TABLE H 3 RATED CAPACITIES FOR SINGLE LEG SLINGS 6x19 and 6x37 Classification Improved Plow Steel Grade Rope with Fiber Core FC Rope Rated capacities tons 2 000 Ib Di Vertical Choker Vertical basket ja inches Constr HT MS S HT MS sS HT s Va 6x19 0 49 0 51 0 55 0 37 0 38 0 44 0 99 1 1 She 6x19 0 76 0 79 0 85 0 57 0 59 0 64 1 5 1 7 k 6x19 14 1 1 12 0 80 0 85 0 91 2 1 24 The 6x19 14 1 5 1 6 44 44 12 29 3 3 6x19 1 8 2 0 24 1 4 15 1 6 37 43 Ne 6x19 23 25 Zr 17 1 9 2 0 46 5 4 5a 6x19 28 31 33 24 23 25 5 6 6 7 Ja 6x19 39 44 48 29 33 3 6 78 9 5 Ta 6x19 5 1 5 9 64 3 9 45 48 10 0 13 0 1 6x19 67 77 8 4 5 0 58 6 3 13 0 17 0 1 6x19 8 4 9 5 10 0 63 74 79 17 0 21 0 114 6x37 98 11 0 12 0 74 83 92 20 0 25 0 1 6x37 12 0 13 0 15 0 8 9 10 0 11 0 24 0 30 0 1 6x37 14 0 1
108. rk ASME B30 9 2010 Slings Safety Standards for Cableways Cranes Derricks Hoists Hooks Jacks and Slings March 2011 The American Society of Mechanical Engineers New York NY Bridon International 2008 Product Catalog Balby Carr Bank Doncaster Code of Federal Regulations 2009 Title 29 Parts 1910 1915 and 1926 Cordage Institute Standard CI 1905 07 May 2007 Synthetic roundslings The Crosby Group Inc rev 01 8 2007 Catalog with product warning and application information Tulsa Oklahoma Federal Emergency Management Agency 2009 Module 4 Lifting and Rigging Structural Collapse Technician Student Manual Hale Iron 1999 Product Catalog Rossville Georgia Handbook of Rigging 2009 Fifth Edition Lifting Hoisting for Construction and Industrial Operations 5th ed McGraw Hill NASA Dryden Flight Research Center Safety and Health Requirements Manual 2008 Chapter 6 Critical Lift DCP S 009 NAVFAC P 307 June 2003 Naval Facilities Engineering Command Navy Crane Center Management of Weight Handling Equipment Noble Denton Guidelines For Lifting operations By Floating Crane Vessels Report No 0027 NDI Uncontrolled Noble House London Oregon Occupational Safety and Health Division Rigging and Rigging Practices Pacific Northwest National Laboratories 2008 Hoisting and Rigging Manual PNNL 18129 Richland Washington Rigging Fundamentals Level One 2005 National Center for Construction Education and Research
109. s allowed an evolution of improvements and significant knowledge being accumulated with regards to its properties and performance This long working history gives it reliability unmatched by other materials and makes it ideal for reducing risk for critical lifts The one main drawback is its size and weight which can make it time consuming to install and fraction of full strength when subject to bending Manufacturers There are many manufactures of wire rope for use as rigging slings such as Bridon Crosby Contental Cabel Diepa Landmann Premier Loosco Peway Python Galin Strand Core Yarbrough and many others Strength and Selection The strength of wire rope varies considerably as the wires themselves can be made of many different types of steel Common wire types are Traction Steel TS Extra High Strength traction EHS Improved Plow Steel IPS Extra Improved Plow Steel EIPS and Extra Extra Improved Plow Steel EEIPS Wire rope intended for service in the marine environment may even be of stainless or monel The core of a wire rope also affects its strength as it may be fiber or of steel wire Furthermore the number and rotation of the wires themselves also affects the strength and general properties This results in significant combinations of wire ropes to be obtained with countless desired properties Unfortunately this results in many things one needs to consider when selecting a specific wire rope An abbreviated list of cons
110. s and Chain shackles can be seen in Table 2 5 8 3 4 7 8 13 8 11 2 13 4 1 33 1 2 3 4 31 4 43 4 61 2 131 2 17 25 06 38 25 11 13 47 31 22 23 53 38 1 47 75 238 2 52 1 25 88 2 81 3 85 1 44 1 00 3 31 1 68 2 72 3 95 15 83 20 80 33 91 13 75 5 18 50 8 31 40 2 88 1 50 1 63 2 00 5 25 1 38 575 1 7 00 1 75 4 19 497 5 83 5 3 5 33 97 156 2 1 16 1 82 31 3 97 69 3 53 4 07 471 06 06 06 06 06 06 31 2 120 265 00 5 25 3 75 14 63 9 8 00 24 63 16 50 4 12 19 00 4 t150 338 00 5 50 4 25 14 50 10 00 9 00 25 69 18 42 4 56 19 75 NOTE Maximum Proof Load is 2 0 times the Working Load Limit Minimum Ultimate Strength is 6 times the Working Load Limit For Working Load Limit reduction due to side loading applications see page 20 Individually Proof Tested with certification Furnished in Anchor style only Furnished with Round Head Bolts with welded handles Table 2 Typical Crosby Shackles Table reprinted with permission from the CROSBY GROUP The Oregon Department of Occupational Safety and Health Division has created a table that matches wire rope sling size to required shackle size which can be found in their rigging and rigging processes handbook part 437 007 0635 This table roughly matches wire rope allowable load based on a factor of safety to minimum breaking strength of 5 and shackle working load and can be referenced i
111. s hidden behind a protective cover there may be little indication that damage has occurred unless the protective cover is also damaged The use of duel protective covers with different colors helps a rigger see if the outer cover is damaged but the outer cover can be damaged Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 33 of 108 without damage done to the internal core fibers Also is it suspected that it is possible that damage can be done to the internal core elements without any visible damage done to the outside cover Until recently the primary inspection technique for roundslings was feeling the core through the outer protective cover a relatively subjective skill that requires significant training to understand what to feel for and how the different components of the core should feel In addition to abrasion problems one must also be award that synthetic slings will be damaged by chemicals and have their strength reduced after exposure to UV or sunlight Both of these forms of damage may or may not be readily apparent as the damage occurs on a molecular level Temperature is also a problem as plastics have a much lower melting temperature as opposed to steel Synthetic slings are relatively new and do not yet have copious amounts of historic data documenting failures and problems as compared to wire ropes This means engineers and riggers must be
112. s no substitute for the application of sound Engineering judgment accompanied with analytical thought This document is part of a packet which includes LIFT CHECK SHEET LIFT APPROACH GUIDANCE RIGGING LIFT COMMON COMPONENT CATALOG For the final analysis and design of any lift ultimate responsibility and application of guidance referenced rests with the user Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 2 of 108 Table of Contents OVERVIEW oi sceiicsiscocccssccaccdaceosccsvessstesecesssesscosseesecscsescenssda sven cesessdecensdeesecssacvsendscvsvensessseseseouseasseases 1 PADEVE wsisisccissscccssvesseccnsiccsccastsea ccsvestecsetectscosvavcs couvessacsdbvsascousescascavessscssvecnscesvasesscavesbacssvesascasves Design Philosophy saaseccsvdecascrscdascesnssastnsagsaacepsizeathcastascunniandtesenaacenvicoasheatiagsorecaadeanseus 8 Standards and Regulations cccccccseceseceeeeeesceeseeceaeceeeeeeeeeeaeeceaeeneeseeeeeaees 10 2 SHACKLES MASTER LINK RINGS c ccseccsscssscosscnsscsevessecssvescestessevessecesccssevesaessovsveessnssunascosssasceeves Manu tac trer Sereni eeaeee e E EAE EE a EE EEEE E EEEa 11 Loading Restrictions and Recommendations ececeeeecceceeeeeceeeeeceeeeessneeeeeneeeenaes 11 Standards and Regulations oo a e asdeasstaaseacnancoiastaadsteciaseaetianteadan da tenseaeaneneeuene 14 Bi SLINGS jcssscesccsscsscs
113. seen in Figure 14 SLINGS RATED LOAD OLD SLING WITH NEW SLING 5 SHRUNKEN NYLON PROCTIVE COVER 10 RATED LOAD NO LOAD PERCENTAGE ELONGATION ON NO LOAD APPARENT LENGTH Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 38 of 108 Figure 14 Approximate Elongation of New Sling vs Old with Shrunken Cover The elastic elongation of Twin Path slings under rated load is similar to wire rope with regards to expected stretch which is quoted as one percent of length at rated load Most other synthetic slings have much greater elongations such as nylon or polyester which typically have elongations of seven percent and four percent respectively The relative rigidity of Twin Path slings can provide some benefit over other synthetic slings as stiffer slings are less likely to cause load control problems Slings that significantly elongate as the load is taken up can cause the initial rigging arrangement to be altered and result in a destabilization of the lifted load A double basket hitch lifting arrangement as shown in Figure 15 is especially vulnerable to destabilization due to sling elongation In this arrangement if an error is made as to the location of the center of gravity one of the lifting slings would take more load causing more elongation and the load to shift in that direction which could lead to a possible run away destabili
114. sling section of these standards primarily reference rope or web slings In terms of use guidance it provides the standard tables for type of hitch and angle of sling These standards also have use guidance based on environmental considerations and safe operating temperatures However there is no information on Synthetic roundslings This is probably because they do not consider there to be enough industry consensus yet developed Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 57 of 108 ASME The American Society of Mechanical Engineers ASME standards for rigging related equipment is one of the most quoted rigging equipment standards The specific ASME standards covering synthetic slings is B30 9 2010 Slings Safety Standards for Cableways Cranes Derricks Hoists Hooks Jacks and Slings which was recently updated in March of 2011 This standard has three chapters on synthetic slings including one chapter 9 6 10 that specifically deals with roundslings their selection use and maintenance This section has several sections including training materials and components fabrication and configurations design factor rated load proof test requirements sling identification environmental effects inspection removal and repair and operating practices This standard references and appears to rely on some of the testing done by the Web Sling and T
115. striction on the title page of this document GENERAL DYNAMICS Page 101 of 108 Figure 35 Use of Hooks Figure reprinted with permission from the CROSBY GROUP Despite the apparent simplicity of hooks there are many ways in which hooks can be improperly loaded Figure 35 and Figure 36 gives some examples of proper and improper loading of some hooks Some hooks are designed with an additional safety latch When using these hooks caution needs to be used to never allow the load to be supported by the latch The latches are not designed to with stand the rated loading of the hooks When using more then one sling on the hook the angle between the hook legs should be less then 90 degrees When threading in the hooks the amount of thread engaged should be no less then 1 thread diameter caution needs to be used as the thread may corrode over time causing the hook weaken and to eventually pull out Side loads back load and tip loads should be avoided when rigging with hooks as many are not designed for these loading conditions VA NY SideLoad Back Load Tip Load Figure 36 Ways of Loading Hooks Figure reprinted with permission from the COSBY GROUP Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 102 of 108 Standards and Regulations The code of federal regulations title 29 part 1926 251 deals with rigging equipment for material handling and su
116. t facilitates better load sharing Some equalizer beams are built with multiple attachment points to maximize their utility In Figure 6 these show up as lines with square points at the locations of functional usage An example of a commercially available model of variable attachment load sharing bar which can be used as a flounder plate or equalizer beam is shown in Figure 7 140 80 SIZE in 3 5 4 45 5 5 5 6 65 i o Figure 6 Parametric Review of Flounder and Equalizer Beams Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 72 of 108 O Oo O OQ ie Oo Oo 0 4 ff yy MODULUS WAA Ht i LIFTING YW WEN LANLA i BEAM dlls sy Figure 7 Variable attachment handling system made for a hook The analysis of a two sling load sharing system hung from one end of a spreader bar results in a system of five equations and five unknowns when certain assumptions are made These assumptions relate to what components length or orientation changes the most and are that the slings do not stretch or elongate significantly under load there are no significant frictional effects in the various pin connections that would prevent rotation and that any localized deflection of the block is far less than the translation that the equalizer plate allows Most importantly it is assumed that the center of gravity of the lifted systems is reasonably known as if this wer
117. t sling forces is inevitably offset some amount from the combined loading point and a moment is then placed on the flounder plate as load is applied The two slings forces must counteract each other so that equilibrium is obtained with the sling tension as a direct function of how close their line of action is to the top loading point as seen in Figure 3 This trigonometric function that results can be relatively complex to solve because the translation and rotation of all members will result when not in equilibrium Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 69 of 108 Figure 3 Offset Line of Action of Sling Forces GENERAL DYNAMICS l Page 70 of 108 Calculation and Standardization of Load Sharing Device Geometry For universally review and analysis of the behavior of flounder plates and equalizer beams a broadly applicable way of categorizing them is necessary The use of a single length dimension of the distance between the sling attachment points allows these tools to be analyzed in a non dimensional way This allows the results to be easily extrapolated across the broad spectrum of plates being used by the shipbuilding industry Figure 4 shows a flounder plate that is designed to be used with a crane hook and the method of measuring the size and aspect ratio of the flounder plate For comparison Figure 5 shows a typical equalizer beam and the typi
118. t was approximately the same and after 50 000 cycles of 150 of the rated load being applied the sling was pulled to failure The sling maintained over five times its original rated capacity and it is believed that this difference is mainly a function of the single degree of curvature of the bearing surface A roundsling bearing onto a cylindrical surface is more likely to have a uniform bearing pressure than a sling on a segment of a torodial surface On a segment of a torodial surface there is also additional pressure since less of the bearing pressures normal force is directly opposite the direction of the pull Furthermore since the maximum strength of a sling requires the full engagement of all filaments in the core and since the filaments on the edge of the sling near the shackles increased curvature are more likely to be under higher load the Crosby test was a more severe test This shows that bunching or any termination that does not promote the even Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 45 of 108 loading of all filaments in the core can degrade the slings strength over time Additional details about this test can be seen in Slingmax technical bulletin number 9B If a typical sling is used 15 times a day fifty thousand cycles represents nine years of service and given the extreme 150 duty cycle loading of the TB9a and TB9b tests done
119. tandardize sling measurements it is suggested that the pins size used should be 2 diameter Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 37 of 108 TWIN PATH SLINGS MEASURED LENGTH 2R MEASURED LENGTH R 2 SLINGS SHOULD BE MEASURED AT 10 RATED CAPACITY SLINGS HAVE DIMENSIONAL TOLERANCE OF 1 FOR 1 lt 40 LENGTHS 2 FOR 40 lt 1 lt 80 LENGTHS 3 FOR gt 80 LENGTHS Figure 13 Twin Path sling length and Measurement It is very important to note that a shrunken cover will reduce the apparent length of the sling under no or minimal load For lifts with multiple slings riggers will correctly try to equalize or balance the load taken by each sling and the apparent shorter sling length may result in adjustments made to balance the initial sharing of the loads However as the load gets drawn up the nylon cover will stretch until the K Spec fibers engage near the original manufactured length Depending on the flexibility of the entire rigging arrangement this lengthening can result in the arrangement relieving that sling of load which is then transferred to accompanying members This has important implications for operations where the length or modulus of the sling is critical under load such as some flounder plate arrangements and other load sharing equalizers An depiction of this elongation versus load effect can be
120. ter roundslings This seems to suggest that to some degree allowable bearing loads from WSTDA have been incorporated by ASME From an rigging engineering perspective very little changed in the 2010 ASME B30 9 update to this chapter One specific comment that was added to the reference table of nominal rated loads Table 25 is that the rated loads shown are based on specific pin diameters and smaller pin diameters will reduce the allowed load This implies a continued movement towards indicating an allowable maximum bearing pressure for roundslings States that twisting of roundslings should be avoided Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 58 of 108 Cordage Institute The Cordage Institute is a organization primarily dedicated to standards for fiber rope and related industries As ropes with synthetic material have developed with increasing capacity standards have been produced to define recommended practices for these products Since roundslings are essentially large bundles of high capacity rope the cordage institute developed a roundsling standard This is standard Cl 1905 07 and most recently published in 2007 and is intended to cover roundslings of any synthetic fiber construction of single or multiple path Topics included relate to the materials for roundslings finishes hitches proof loading break testing identification responsibi
121. ter slings are Twin Path slings similar to the TPXC available up to 50 short ton capacity and are rated up to 300 F Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 53 of 108 Chemical and Environmental Considerations K Spec The core fiber of Twin Path extra with Covermax slings are made of the K Spec fiber of which the exact blend is a trade secret The primary fibers include aramid such as Technora and high molecular polyethylene such as Spectra and chemical considerations are similar to the component fibers The K Spec core yarn strength retention is based on tests results of components at 150 F or less for 6 months 100 Strength Retention when exposed to Age 10 detergent solution rot and mildew sunlight and Toluene 99 Strength Retention Acitic acid gasoline one molar solution of hydrochloric acid hydraulic fluid Kerosene seawater 98 Strength Retention 25 ammonium hydroxide 10 hypophosphate solution 40 phosphoric acid 97 Strength Retention 5 molar solution of sodium hydroxide 95 Strength Retention Portland cement and sulfuric acid 88 Strength Retention Clorox and nitric acid Nylon The most common cover used with Twin Path slings is the green and red bulked nylon cover referred to as Covermax Nylon is acommon material for rigging slings with a long history of use and significant data available A brief overview of
122. th a known block center of gravity the exact load in a particular sling represents a statically indeterminate problem Without equalizer plates the specific forces in each sling depends entirely on the exact length and stiffness of the sling along with the blocks rigidity along with other geometric factors of the global rigging arrangement Wire rope and high strength synthetic slings are relatively stiff with elongations of about a quarter of one percent and one percent respectively at the full rated load This means that total elongation for a fully loaded 30 foot long wire rope sling is less than one and a half inches and the relative difference between two of such slings loaded at 80 and 50 percent of capacity would be expected to be on the order of 3 8 of an inch As the manufacturing tolerances of wire ropes are on the order of a half a percent the sling length or almost two inches for the 30 foot sling mention above the Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 79 of 108 importance of soft connection devices such as equalizer or flounder plates that facilitate the small length adjustments necessary to evenly distribute the loads are clear Similarly as lifted deflections of bulkheads in large multistory blocks can be shown to be minimal the importance of soft connection devices for safe operations is necessary Since the assumption that equalizers
123. the outside of the sling to help increase bearing strength abrasion resistance and strengthen terminations Depending on the capacity and length of the sling required the winding of the core fibers will vary slightly The K Spec yarns are woven into cords with an unloaded diameter of roughly five millimeters and in spool lengths of hundreds of yards long There are some slight variations on roundsling manufacturing processes but these cords are essentially wound between two sheaves or driver rollers that are set at the required distance apart to result in the finished sling having the specified length For high capacity slings of long length a very significant number of wraps are often required which results in a total core Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 35 of 108 length greater than a typical spool of K Spec fiber After the first cord spool is wrapped to its entirety the ends are tied together and wrapped with tape similar as shown on the left of Figure 12 and another cord spool is started This process is continued until the total number of loops of the core fibers is greater than the calculated number to meet the strength requirements The exact process Slingmax uses has added a slight twist such that the there is a helical winding of the individual core fibers similar to wire rope which should allow for a better transfer and distribu
124. the padeye if out of plane loads are anticipated The types of structures the padeye will be welded will also influence the geometry of the padeye If the structure is relatively thin in Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 8 of 108 comparison to the padeyes thickness the padeye may need to be lengthened to spread the load over a greater length of the thin block structure Also whether the padeye is just used with only vertical loads or if the padeye is intended for turning operations with horizontal loads will greatly affect the shape at the attachment to the structure Turning operations may require a padeye to be loaded through 180 degrees during a single lift This often requires a padeye to have its shackle hole extended over the end of the structure that it is attached Two approaches to this problem are to lap the padeye onto the structure and to cantilever the padeye out over the edge From the designs reviewed there seems to be no clear consensus as to the best way to do this or what the best geometry might be Figure 2 Blade and Lap On Padeyes Used For Turning One approach to lifting and turning operations is with the use of trunions Typically these are cylindrical posts sticking proud that a sling or line can be wrapped around This arrangement can allow loads to be applied in any direction
125. tion of load among the core fibers For slings with multiple paths such as Twin Path slings this winding process in completed in parallel in both of the path sections Figure 12 Component Construction of a Single Path Roundsling Strength Twin path Extra slings are readily available in sizes ranging from 5 to 250 short ton vertical rated capacity These standard sizes are usually more than sufficient for almost all shipyard applications as the relative local strength of ship modules often dictates the amount of load that can be placed at any one specific spot without the addition of significant temporary structure The vast majority of lifts at shipyards have loading of less than 100 tons per attachment point and often slings capacities are selected based on these requirements The construction and offshore industries do occasionally have the need to have larger capacities and K Spec _ roundslings have been made with ratings of 660 short tons although in this specific configuration as Tri path slings All standard slings sold are rated to ensure a five to one design factor between rated capacity and estimated failure load Although ASME does not require the proof testing of new slings that do not have previously used or welded fittings all Twin Path roundslings are loaded to twice the rating after manufacture Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS
126. tions for Polyester is as follows Polyester will disintegrate when in contact with concentrated sulfuric acid Polyester is resistant to aqueous solutions and strong alkalis at room temperatures however when brought to boil these substances will destroy the material Polyester s strength is not affected by moisture Aramid Aramids are affected by strong acids bases and sodium hypo chlorite bleach especially at high concentrations and temperatures Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 55 of 108 Standards and Regulations OSHA The Occupational Safety and Health Act OSHA is the main federal law intended to promote safe working conditions for employees in U S Territories Part 1910 of Title 29 of the Code of Federal Regulations CFR carries out the directive of the Occupational Safety and Health Act In addition the act included a general duty clause was included requiring employers to provide a work place free of recognized hazards These standards incorporated into the different parts are intended to make any national consensus standards law such that widely adopted and agreed upon safe practices are promoted For the most part OSHA has not updated its standards that pertain to slings which were originally heavily based on ASME s standard for slings B30 9 at the time of execution This means that any newly developed materials o
127. tween them being almost 180 degrees and the lines themselves being at almost 90 degrees from in line it can easily be seen how this load orientation could reduce the strength of the shackle With this extreme loading condition significant bending forces will be placed in the shackle and the pin will be under tension Crobsy has recommendations to derate the shackle under these conditions as shown in Table 1 It should also be noted that it is never acceptable to put these extreme loading condition on a shackle with the pin held in place with a cotter pin as this configuration will not handle tension ihe inthe For Screw Pin and Bolt Type Shackles Only t P4 45 PRA DEGREES Apa ot Hda Load 7 y from Vertical In Line of shackle Adjusted Working Load Limit N 7 ae d A X 100 of Rated Working Load Limit i on 45 from In Line 70 of Rated Working Load Limit j 90 f Angle loads must IN LINE Side Loading Reduction Chart f 90 from In Line 50 of Rated Working Load Limit In Line load is applied perpendicular to pin L od DEGREES DO NOT SIDE LOAD ROUND PIN SHACKLES TT any YA j IA P EL n e Table 1 Side Loading Load Reduction Table reprinted with permission from the CROSBY GROUP Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 12 of 108 Typical sizes and strengths of Crosby G shackle
128. ty for Wire Rope in psi Figure reprinted with permission from the WIRE ROPE TECHNICAL BOARD End Connections There is a large variation in the types of end connection possible with wire rope The two main types are splices and sockets Splices are typically used with a thimble and are not as strong as sockets because of the bend radius that the line is subjected They will also be subject to a shortened life due to fatigue Wire rope sockets contain the end of the wire typically with a poured zinc or resin plug Other plug material can be used however they vary with strength and validation of their strength should be confirmed Typically for critical lifts sockets are used that allow the rope to provide its full strength Closed spelter sockets which are ideal for connecting to the round of a G shackle and can be obtained with safe working loads of hundreds of tons Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 21 of 108 WIRE ROPE SOCKET pounso SPELTER OF RESIN mae D o 2 WIRE ROPE SOCKET swasen LOOP OR THIMBLE SPLICE HANO TUCKED Figure 7 Types of Wire Rope Ends Figure reprinted with permission from the WIRE ROPE TECHNICAL BOARD Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 22 of 108 Efficiency Type of Termination Rope with IWRC Rop
129. uld be ensured to conform to these requirements if specifying for a lift requirement Table 13 below gives the allowable chain loading based on chain size straight pull for grade 80 and 100 alloy steel chain manufactured by Cosby The tables give the working limits in pounds of the chain with a design factor of 4 to 1 Working limits of chain should be further reduced if chain is used as a choker to account for the angular choke similar to wire or synthetic slings a minimum angle of choke of 120 degrees is recommended Spectrum 8 Alloy Spectrum 10 Alloy Chain Size Chain Size i Leg 1500 35300 59700 Table 13 Load Ratings based on Chain Dimensions Figure reprinted with permission from the CROSBY GROUP Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 62 of 108 Chain experiences a reduction in strength when exposed to high temperatures although is much more suitable for high temperature than synthetics or wire rope Table 14 below give the percentage reductions based on the temperatures Normal operating temperatures for slings are from 40 to 400 degree Fahrenheit For the most part these temperature extremes are outside of any probable expectations for a typical shipyard unless casting of specific parts is actively performed Chemical interaction should also be considered when working in chemically active environments USH 910 zR requr
130. unted to the side of the buildings using one wall of the building for support Whirly Mobile Figure 37 Whirly Mobile Cranes at NASSCO Mobile crane is made up of a truss latticed or telescopic boom which moves around on rails wheels or caterpillar tracks The boom which is hinged at the bottom is raised and lowered by cables or hydraulic cylinders Hooks are suspended from the boom by wire ropes which are operated through a variety of transmissions Mobile crane with caterpillar tracks are typically referred to as crawlers and have hydraulic extendable supports which can increase stability but eliminate mobility Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 104 of 108 Figure 38 Typical Crawler Crane Standards and Regulations OSHA 1926 Subpart N Cranes Derricks Hoists Elevators AND Conveyors 1926 550 Cranes and Derricks ASME B30 2 1990 Overhead and Gantry Cranes Crane Certification Association of America Crane Manufacturers Association of America Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 105 of 108 References ASME B30 2 B30 4 B30 7 B30 11 B30 17 2005 Safety Standards for Cableways Cranes Derricks Hoists Hooks Jacks Slings Below the Hook Lifting Devices American Society of Mechanical Engineers New York New Yo
131. ure This indicator is a completely separate cord wrapped in each core of the sling which is designed to break when the sling is Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 50 of 108 significantly overloaded on the order of two to four times the slings rated capacity As load and elongation are directly related the EWI will break when the sling is stretched to an amount slightly greater than occurs during the sling s proof load recoiling inside the cover The recoil of the EWI breaking will cause its somewhat arbitrary length external tell tails to disappear completely into the roundsling providing sufficient notification to users that the sling has seen excessive load and should be removed from service for factory inspection and repair During normal operation the rendering of a sling can sometimes cause the EWI tell tails to shift location slightly and therefore the length that protrudes from the cover but so long as it has not disappeared entirely the sling can be consider safe One of the features of the check fast system is the check fast tag which indicated to the rigger that a tell tail should be present This is an important feature as it allows a rigger to distinguish between a sling that has potentially been overloaded and an older sling that does not have the check fast system incorporated into it An additional inspection method for Twin
132. ure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 25 of 108 Standards and Regulations The Code of Federal Regulations CFR sets criteria for different uses of wire rope OSHA provides tables H 3 to H 14 in 29 CFR 1926 251 with ratings for wire rope capacity for a few selected different types and configurations These are the same tables or almost identical to tables which can be found in ASME B30 9 standards for slings Wire ropes may have working loads higher than those provided in the tables provided the breaking strength is five times higher than the intended load If one knows the straight pull or vertical rated capacity of the cable the bend radius that it may be subjected to as well as the efficiency of the termination basic trigonometry can be used to find the exact rated strength for any angle Figure 11 below shows the configurations of the five different arrangements which are used in the OSHA tables on Lv Vertical Choker Basket 2 Leg 3 Leg Figure 11 Statically Determinant Lift Arrangements Covered by OSHA Regulations The rated capacities given by OSHA are of limited use by shipyards rigging personnel designing critical lifts since most of the lifting arrangements used do not confirm to the basic configurations shown in Figure 11 Furthermore it should be understood that many manufactures have wire ropes that exceed the st
133. ving each sling share the load equally it should be known how to measure them When specifying the length of wire ropes they should be measured by the distance between the two pull locations or the center of the pin to be pulled in the socket An example of measure lengths are shown in Figure 6 Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 19 of 108 Length m Length of Loop he Length ea 4 S Length n Figure 6 Wire Rope Length Measurements Figure reprinted with permission from the WIRE ROPE TECHNICAL BOARD Strain and Modulus The stretch of a wire rope is dependant on two factors First there is the elastic stretch of the steel elements that elongate in proportion to the modulus of elasticity of the metal An equally important component for wire rope is the structural stretch cause by the compression of the rope core and adjustments of the wires in the rope This component can vary due to many factors such as the type of core the length of the lays the amount of bending the rope is subjected or has seen vibration and the complete load history of that particular wire rope Older wire ropes that have seen heavy duty cycles will see less elongation than new ropes during loading The structural stretch of the wire rope will also cause the wire rope to twist as it unlays For very long lengths of wire rope a swiv
134. vstecseoseticceesetecconsssusccessscaseessbssceesstusseovesnssbevssvuneesesss VET ACO ES seinere ga d nE e E ETER are 93 End Connections fsinascnitiintonncnminmndtramsbiinnmGransinmmnansilblmimnanimnyies 93 Standards and Regulations ccccccecscccesssecssssesesseecesseecseeeecsseeecsneeecsseeeeseees 93 Al wable DEGAS i ssdensadesvnncusnsantencennpeddvanncuadsanvdtaess asetenacnvprdssneaniuncaniacnrannteupnentandenstan 94 Sizes and Standard Types scsisiicecrcaenssacisne canines 95 Ti HOOKS E A E E E Size and Stren th eissien anea ooi ae i ii aani 101 8 CRANES weiss ssscsssossssccesssececsesnecacsossdeeaseeseeacsessvennsesdeenckesstenndessevnnsessvinndesdevnesessdvendssssdecudssviensvessvnes Standard 1 OS neirens Pentair exes AAA EE ae 104 Standards and Regulations ccccceccsecessseeesseecesseecseeeecsseeeceececsseeecseeeesaes 105 Figures Fi re l Ex mples of Pade yes ccc daencdaureveevnatacoscevdnecsssvcuadeeseeaadeeedue ed cunysteeaysoananeesoreedsasaace 8 Figure 2 Blade and Lap On Padeyes Used For Turming eeeeseeeseeeeeeeeeeeeeenneeneenees 9 Figure 3 TrM nnes eire i mee renner men AT E en en ervers eer terry R 10 Figure 4 Selection of Typical Shackles sssseseessssessesosrersssrssessssnsissessrsssiesrrsriseeessssessess 11 Figure 5 Recommended Distributed Loading of Shackle Pins 12 Figure 6 Wire Rope Length Measurements eseseeeeseseeseesrrssreresserserrersresrsreesressesreesee 20
135. zation resulting in failure These non linear load shifting effects due to sling elongation are also very difficult to fully account for during the engineering design of lifts and having a relatively rigid sling makes this complication less critical It should be noted that for most synthetic slings the elongation with load is not linear as slings will get stiffer with increasing load No specific plot of load against elongation has been published for Twin Path slings 4 HA Ye p WA zo Construction stretch The manufacturers of Twin Path slings currently state that these slings do not have construction stretch or a slight elongation of the slings shortly after leaving the factory and after being broken in with moderate use When manufactured the slings are constructed to have a 5 to 1 ratio between breaking strength and rated load However after some use slings have often been quoted to have increased strength with ratios observed approaching 6 to 1 The explanation of this is that the manufacturing process has some inevitable variance included which does not guarantee that the load is evenly distributed among all yarns and inevitably some cords in the core are slightly longer and Use or disclosure of data contained on this page is subject to the restriction on the title page of this document GENERAL DYNAMICS Page 39 of 108 thus take less load As the sling is used the cords in the core adjusted themselves

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