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Foundry Magazine Safety Feature

Safety is the key feature when selecting and using lifting gear.

Safety Safety has always been paramount in the lifting industry and equipment designed for use in foundries is no exception. From lifting beams, through to overhead runway systems, large cranes, and hoists, every working component must be tested with increased regularity. There is no escaping these requirements. Recent changes in legislation have put the responsibility for carrying out maintenance checks and training in safe practice firmly on the shoulders of those buying and using the equipment.

The two most important pieces of lifting legislation relevant to foundries are the Provision and Use of Work Equipment Regulations (PUWER) reissued in 1998, and, more recently, SI 2307 Lifting Operations and Lifting Equipment Regulations (LOLER). Legislation insists that all equipment must be safe and suitable for its intended use and tested in accordance with rigid examination procedures.

Depending on the type of equipment, routine examinations must be carried out every six or 12 months by a competent person and any piece of equipment must be thoroughly examined as a matter of course following any exceptional circumstance. Manufactures and suppliers must, by law, provide information on the safe use of their equipment as required by the 1974 Health And Safety At Work Act. The Lifting Equipment Engineers Association (LEEA) also gives recommendations on the safe use of lifting gear but ultimately it is now up to the company owning the equipment to provide records of conformity, testing and examination.

Not surprisingly, heavy duty users are opting to buy-in specialist testing and examination services. It gives peace of mind, and, in the long run, proves more cost effective. Certex, as an example, has introduced a Lifting Equipment Management Inspection Service (LEMIS) whereby companies are supplied with a self-contained rigging loft of loose components. The loft – often carrying up to 100 pieces of lifting tackle at any one time – arrives fully stocked and colour-coded and is routinely checked and replaced by qualified engineers every six months. The service was first developed for the offshore industry where large amounts of equipment were hired on long-term contracts with products sometimes expiring before the payment period. The rigging loft not only allows users to re-select items as and when their lifting requirements change, but it predetermines running costs in advance. Savings of up to 15% in equipment examination and management costs make it a viable service for many users.

Training

With safety high on the agenda, a whole raft of additional training courses has emerged. Suppliers actively encourage operators to attend short courses in different aspects of handling lifting gear from basic wire rope splicing and socketing through to crane inspection. A good quality course will last up to three days, depending on the subject, and will provide certificates of attendance. Certain courses are approved by relevant industry bodies and may be eligible for grants.

Chain and wire rope

The design and manufacture of lifting products has also changed in accordance with safety legislation. Improvements in the quality of chain, for example, have been dramatic in recent years. Size has reduced substantially relative to loading capacity with chain being much lighter, more manageable, and safer to use. The most widely used chain is made by Kuplex. It is usually supplied in 50-100m lengths with chain assemblies either supplied made up or as separate components.

Wire ropes, meanwhile, have become more durable. The Endurance Dyform range made by Bridon is a typical example and probably the most widely used in foundries. It is available in various strengths up to 2160 grade and is supplied made up and cut to length as required by the user. The Endurance Dyform 6 is especially suitable in high temperatures having an increased life; a solid steel core designed to resist crushing when coiled under pressure; an in-built heat resistant lubricant, and a high breaking force. The main advantage of long life ropes is the reduction in down time enabling increased productivity and the guarantee of a planned maintenance schedule. It’s also worth mentioning that most high endurance wire ropes are best suited to run over larger diameter sheaves and drums to avoid bend fatigue. Certain brands are more susceptible than others – a point worth checking with suppliers before purchasing.

When wire ropes are to be joined, heavy-duty use demands hard working methods. Bull dog grips tend to slip (the BS462 standard was withdrawn due to efficiency rates as low as 20% in certain cases) and suppliers tend to recommend alternative joins such as ferrules, hand splicing, wedge sockets or sockets filled with white metal or zinc. If fixings are carried out on site it is imperative that operators are fully trained and adhere to manufacturers’ recommendations on safe practice.

Lifting beams

Safety From 1 tonne swing jibs through to 120 tonne lifting beams, products are generally fabricated to specific requirements and delivered ready for commission. Reputable companies offering this service will advise on the most suitable specifications and will offer bespoke beams as well as standard products.

Hoists

Chain hoists have developed considerably over the years from manual hoists through to more modern electric and pneumatic models. Leading names in this market are Elephant and Yale – both of which supply products to a range of specifications including low head room, strength, speed, reliability and durability. Powered chain hoists are precision tools with built-in safety features such as an adjustable slip clutch which is fitted as an overload safety device and engineered for low maintenance. A slip clutch also serves as an overrun protection for the highest and lowest load hook positions. All electric and air powered hoists are factory tested with overload. They are supplied with a certificate showing their serial number and an operating instruction manual containing an EC declaration of conformity.

Lifting clamps

Safety The latest development in lifting clamps is the IP range. Designed by Netherlands manufacturers, Inter Product bv, the company has launched two new additions, the IPU10/A, designed with an automatic locking clamp guaranteed not to slip on heavy loads, and the IPTPU, developed for moving and turning large steel plates through 180 degrees without them buckling. The IPUV/A is by far the most innovative clamp available on the market with the capacity to hold single loads of up to two tonnes. The IPTPU, on the other hand, is especially constructed to keep large metal plates intact and comes with a clever hoisting eye enabling operators to lift loads safety from any direction. The clamp has a jaw aperture from 0-15 mm and a working load limit of up to 3000 kgs.

Magnetic lifters are also proving popular. The Ultralift, made by Eclipse Magnetics, guarantees safe lifting regardless of the weight of the load, poor contact surface or uncertain alloy content. A built-in pre-test method using a ‘Safety Shim’ allows the operator to make sure that the magnet will work prior to actual lifting. The Safety Shim introduces a known air gap between the Ultralift and the component, calibrated to reduce the lifting force by a factor of three. If the magnet will lift the component with the Shim in place, the operator then knows that without it, the magnet will lift with a guaranteed safety factor of 3:1. For longer length components multiple magnetic lifters are used in conjunction with a spreader beam. More complex lifting requirements may need custom-built magnetic lifting systems.

Computerised product management

Certex has worked with customers in the steel, iron and fabrication industries to develop a bespoke software system that simplifies lifting gear inspection and certification. The system, known as CertMan stores product histories, maintenance schedules and inspection reports all of which can be instantly retrieved through a simple database. The system is unique and is accessed via the Internet including a ‘live’ electronic messaging service and an early warning system that highlights items due for inspection. Defective products are tracked and colour coded to prevent them from being brought back into use. CertMan can be operated from the shop floor via a laptop and will print out both risk assessments and examination reports meeting the requirements of schedule 1 of LOLER (SI 2307), all from remote locations.

Where next?

Regulations surrounding lifting gear are likely to tighten further in the not too distant future. There is talk of a review of the Health and Safety At Work Act is due during 2003/4 and if this proves to be the case, safety and maintenance requirements will be even more stringent than those demanded by LOLER. Inspection and testing services from experienced independent engineers will play an even larger part in the safe running of industrial sites.