Bullivants Excerpts from Australian Standards Book by Bullivants

H A N D L I N G

S A F E T Y

EXCERPTS FROM AUSTRALIAN STANDARDS

VERSION 9 15- 10/02/2015 - 31/01/2023

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Authority: AJT, Date: 31/01/2023 ONLY: UNCONTROLLED Issue: 1, Revision: 9, Authority: AJT,REFERENCE Date: 10/02/2015, REFERENCE ONLY: UNCONTROLLED Bullivants | Page 1 of 692

Using the Electronic Version of the Excerpts It is very easy to navigate the electronic version by using either the bookmarks or the index. To use the index, hover over the standard or description you wish to go to, you’ll notice the pointer turns into a small hand, simply click and it will take you to the first page of the document you have selected.

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The purpose of this document is to provide the user with applicable information from Australian or International Standards. It is the responsibility of the user to make him/her aware of ALL the requirements, mandatory and advisory of the selected standard. The technical information contained in this publication should not be relied upon for specific applications without first securing competent advice. Whilst all care is taken to ensure that information contained herein is accurate and up to date, Bullivants does not warrant its accuracy or completeness and does not accept liability for any errors or omissions. For the latest versions of Standards & Procedures refer to company intranet and management systems database.

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EXCERPTS FROM AUSTRALIAN STANDARDS

Page # 3 4 6 7 8 18 24 32 34 39 42 48 52 54 60 132 145

Aust Standard No

AS1138 ‐ 2008 AS1353.1 ‐ 1997 AS1353.2 ‐ 1997 AS1380.1 ‐ 1998 AS1380.2 ‐ 1998 AS1418.1 ‐ 2021 AS1418.2 ‐ 1997 AS1418.3 ‐ 1997 AS1418.17 ‐ 1996 AS1418.18 ‐ 2001 AS1657 ‐ 2013 AS1666.1 ‐ 2009 AS1666.2 ‐ 2009

154

AS1891.1 ‐ 2021

162 173

AS1891.2 ‐ 2001 AS1891.2S1 ‐ 2001

190

AS1891.3 ‐ 2020

192

AS1891.4 ‐ 2009

205

AS1891.5 ‐ 2020

211 229 232 237 244 248 255 282 285 287 313 320 323 327

AS1892.1 ‐ 2018 AS1892.2 ‐ 1992 AS1892.3 ‐ 1996 AS1892.5 ‐ 2020 AS2076 ‐ 1996 AS2089 ‐ 2008 AS2317.1 ‐ 2018 AS2318 ‐ 2006 AS2319 ‐ 2001 AS2321 ‐ 2014 AS2359.1 ‐ 2015 AS2359.6 ‐ 2013 AS2550.1 ‐ 2011 AS2693 ‐ 2007

INDEX

Description Design Factor Introduction Index Ethical Conduct Policy Lifting Plan Poster Thimbles for Wire Rope 5 Flat synthetic webbin slings Part 1: Product Specification 8 Flat synthetic webbin slings Part 2: Care & Use 8 Fibre Rope Slings Part 1: Product Specification (Ref Only) 5 Fibre Rope Slings Part 2: Care & Use (Ref Only) 5 Cranes, Hoists & Winches Part 1: General Requirements 4 (Min) Cranes, Hoists & Winches Part 2: Serial Hoist & Winches 4 Cranes, Hoists & Winches Part 3: Bridge, Gantry, Portal & Jib Cranes 4 Cranes, Hoists & Winches Part 17: Design & Construction of Work Boxes 10 Cranes, Hoists & Winches Part 18: Crane Runways & Monorails Fixed Platforms, Walkways, Stairways & Ladders Wire Rope Slings ‐ Product Specification 5 Wire Rope Slings ‐ Care & Use 5 Personal Equipment for Work at Height ‐ Manufacturing Requirements for Full Body Combination and Lower Body Harnesses 2 Industrial Fall Arrest Systems & Devices ‐ Horizontal Lifeline & Rail Systems 2 Industrial Fall Arrest Systems & Devices ‐ Prescribed Configurations 2 Personal Equipment for Work at Height ‐ Manufacturing Requirements for Fall Arrest Devices 2 Industrial Fall Arrest Systems & Devices ‐ Selection, Use & Maintenance 2 Personal Equipment for Work at Height ‐ Manufacturing Requirements for Lanyard Assemblies and Pole Straps 2 Portable Ladders ‐ Performance and Geometric Requiements Portable Ladders ‐ Timber Portable Ladders ‐ Reinforced Plastic Portable Ladders ‐ Selection, Safe Use & Care Wire Rope Grips for Non‐Lifting Applications Sheave Blocks for Lifting Purposes 5 Collared Eyebolts 6 Swivels for Lifting Applications 5 Rigging Screws & Turnbuckles 6 Short Link Chain for Lifting Purposes 4 Powered Inductrial Trucks Powered Inductrial Trucks: Self propelled industrial trucks Cranes, Hoists & Winches ‐ Safe Use Vehicle Stands CONTINUED NEXT PAGE

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EXCERPTS FROM AUSTRALIAN STANDARDS

Page # 333 336 347 362 368 377 392 415 426 431 442 446 450 454 458 474 477 485 498 505

Aust Standard No AS2740 ‐ 2001 AS2741 ‐ 2002 AS2759 ‐ 2004 AS2865 ‐ 2009 AS3569 ‐ 2010 AS3775.1 ‐ 2014 AS3775.2 ‐ 2014 AS3776 ‐ 2015 AS3777 ‐ 2008 AS3785.7 ‐ 2006 AS3850.1 ‐ 2015 AS4344 ‐ 2001 AS4345 ‐ 2001 AS4380 ‐ 2001 AS4497 ‐ 2018 GSO/0212 AS4722 ‐ 2009 AS4797 ‐ 2009 AS4812 ‐ 2003 AS4991 ‐ 2004

522

AS5532 ‐ 2013

526

AS18264 ‐ 2022

570 579 588 607 612 621 629 635 650 651 665 669 681 682 683 692

AS EN 12079.1 ‐ 2010 ISO ‐ 17025 IT‐LAHS GSO/ITP/0411 IT‐VI/O IT‐OLE PO‐FV‐SC

Updated

INDEX (Continued)

Description Wedge Type Sockets Shackles Steel Wire Ropes ‐ Use, Operation & Maintenance Confined Spaces Steel Wire Ropes ‐ Product Specifications Chain Slings for Lifting Purposes Chain Slings for Lifting Purposes ‐ Care & Use Lifting Components for Grade 80 & 100 Chain Slings Shank Hooks & Large Eye Hooks Max 60t Underground Mining ‐ Shaft Equipment ‐ Part 7 Sheaves Prefabricated Concrete Elements Motor Vehicles ‐ Cargo Restraint Systems ‐ Transport Chain & Components Motor Vehicles ‐ Cargo Restraint Systems ‐ Transport Fibre Rope Motor Vehicles ‐ Cargo Restraint Systems ‐ Transport Webbing & Components Round Slings ‐ Synthetic Fibre Visual Inspection of Synthetic Items marked with Pen or Paint Passenger Ropeways and Passenger Conveyors Stainless Steel Chain for Lifting Purposes NDE & Discard Criteria for Wire Rope in Winding Systems Lifting Devices Manufacturing Requirements for Single Point Anchor device used for harness based work at heights Textile Slings ‐ Lifting Slings for general purpose lifting operations made from fibre rope ‐ HMPE Offshore Containers & Associated Lifting Sets NATA (FAD) Rules (V2018) Inspection, Testing & Reporting Lifting & Height Safety Equipment Control of Inspection & Test Equipment Visual Inspection of Rigging Appliances (OFFSHORE) using Checklists Inspection, Examination & Testing of Offshore Lifting Equipment & Sets Service & Test of Manual Chain & Lever Blocks, Electric & Wire Rope Hoists Ferrule Pressing Charts Crane Signal Card Rigcheck Card Weights & Measures Maintain Lifting Equipment Branch Locations Caterpillar Lifting Link Bracket Inspection Criteria for HMPE Rope Standard FST Tool Kit

Design Factor 5 6

4 4 4 5 5 2 2 2 7 5 4 1.5 (min)

Denotes updates in this version ‐ 31/1/2023

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Wesfarmers Industrial & Safety (“WIS”) and its business units are committed to the highest standards of conduct and ethical behaviour in all of their business activities, and to promoting and supporting a culture of honest and ethical behaviour, corporate compliance and good corporate governance. The Ethical Conduct Policy is to encourage suppliers, contractors, customers or any other party to raise any concerns and report instances of unethical, illegal, fraudulent or undesirable conduct, where there are reasonable grounds to suspect such conduct, without fear of intimidation, disadvantage or reprisal. WIS relies on the parties that it does business with to help the company achieve its commitment to a culture of honest and ethical behaviour, corporate compliance and good corporate governance. For WIS, the failure to report actual or suspected incidents of Unethical Conduct will be treated seriously and may adversely affect the ongoing business relationship. Unethical Conduct covered by this Policy includes any conduct of a director, officer, employee, contractor or third party, whether actual or suspected, including:   



dishonest, fraudulent, corrupt or illegal conducts; unethical actions or behaviours (including bribes, facilitation payments or other kick-backs, inappropriate gifts; falsifying documents or other unacceptable or unethical behaviour); actions that have the potential to damage WIS’ property, people or reputation or that of another party (such as unsafe work practices, environmental damage, health risks or substantial wasting of company resources); or abuse of authority, threats, intimidation or harassment.

Unethical Conduct can be reported to:  

the employee’s immediate supervisor or manager or another senior person; or the Ethical Conduct email hotline on ethical.conduct@wisau.com.au and these matters will be confidentially referred to the WIS Managing Director or Chief Financial Officer.

While the person reporting the issues may wish to remain anonymous, if contact details are not provided, sufficient details will need to be included in the report to allow the matter to be investigated. WIS will investigate all reports of Unethical Conduct in a timely, thorough, confidential, objective and fair manner (subject to considerations of the privacy of those against whom allegations are made).

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AS 1138—2008

Australian Standard® Thimbles for wire rope

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CONTENTS 1 2

Page SCOPE .............................................................................................................................. 4 REFERENCED DOCUMENTS ...................................................................................... 4

DEFINITIONS ................................................................................................................. 5

MATERIALS ................................................................................................................... 9

DESIGN AND MANUFACTURE .................................................................................. 9

MECHANICAL PROPERTIES ..................................................................................... 12

MARKING ..................................................................................................................... 12

TESTING OF MECHANICAL PROPERTIES ............................................................. 12

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APPENDICES A INFORMATION THAT SHOULD BE SUPPLIED WITH ENQUIRIES AND ORDERS ......................................................................................................................... 14 B

STANDARDS FOR COMPONENTS USED IN LIFTING SYSTEMS ......................15

CONDITIONS FOR APPLICATION OF TEST FORCES ..........................................16

MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD ......17

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AS1138 - 2008

3.8 Thimble

3.8.1 General A fitting that, while retained within an eye formed at the end of a wire rope, will reinforce the eye and obviate damage and wear to the wire rope from any connected lifting tackle or other connection.

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NOTES: 1

A typical attachment of a thimble to a wire rope by a ferrule secured eye is illustrated in Figure 3.8.1(A).

A typical single-leg wire rope sling with ferrule-secured eyes is illustrated in Figure 3.8.1(B).

A typical section though the crown of ordinary, reeving and contiguous thimbles is shown in Figure 3.8.1(C).

FIGURE 3.8.1(A) TYPICAL ATTACHMENT OF A THIMBLE TO A WIRE ROPE BY A FERRULE SECURED EYE

FIGURE 3.8.1(B) TYPICAL SINGLE-LEG WIRE ROPE SLING WITH FERRULESECURED THIMBLE EYES

F H G J

FIGURE 3.8.1(C) SECTION THROUGH CROWN OF ORDINARY, REEVING AND CONTIGUOUS THIMBLES

3.8.2 Ordinary thimble A thimble by which a fitting can be attached to the end of a wire rope in such a manner that the fitting is capable of full articulation (see Figure 3.8.2).

3.8.3 Reeving thimble A thimble, of internal dimensions adequate to permit the eye of a wire rope, reinforced with a thimble to the same size, to pass through (see Figure 3.8.3).

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AS1138 - 2008

3.8.4 Contiguous thimble A thimble manufactured without a join (see Figure 3.8.4).

3.8.5 Solid heart thimble A thimble that has a cylindrical hole passing laterally through it to permit it to be secured by means of a pin, bolt, or similar fastening (see Figure 3.8.5).

B B

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(i) Without point or gusset A

(ii) With point without gusset A

B B

(iii) Without point with gusset

(iv) With point and gusset

(v) In the open condition

FIGURE 3.8.2 TYPES OF ORDINARY THIMBLES

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AS1138 - 2008

(i)

Without point

(ii) With point

FIGURE 3.8.3 TYPES OF REEVING TIMBLES

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FIGURE 3.8.4 CONTIGUOUS THIMBLE

Op tional lightening hole (se e Note in Clause 5.2)

Optional bosses Hole

Optional bosses

E H

FIGURE 3.8.5 SOLID HEART THIMBLE

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AS1138 - 2008

4 MATERIALS Thimbles should be manufactured from iron or steel complying with one of the specifications listed in Table 1. The use of other grades of iron or steel or other materials is not precluded, provided they suit their purpose. TABLE 1 SPECIFICATIONS FOR RECOMMENDED MATERIALS

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Australian Standard Grades

Grades

AS 1442 AS 1443 AS 1444

K1022 to K1045 CD1 to CD4 8620 to 4140

AS 1446 AS 1448

K1022 to K1045 K1020 to K1040 and XK1320

AS/NZS 1595 (see Note 1) AS 1831 (see Note 2) AS 2074

CX1 370/17 or 400/12 C3

AS/NZS 3678 AS/NZS 3679.1

Any Any

NOTES: 1

Only for ordinary thimbles and reeving thimbles.

Only for solid heart thimbles.

5 DESIGN AND MANUFACTURE 5.1 General Ordinary and reeving thimbles shall be either forged or made from rolled steel section. Contiguous thimbles may be cast or forged. For larger ropes, or where ropes have higher capacities, thimbles with dimensions that differ from Table 2 may be fabricated, forged or cast to achieve the required mechanical properties. Where fitment of a large eye hook or other fitting to the thimbled eye is required, this should be specified at the time of ordering to ensure interfacing of fittings can be achieved. Except for cast solid heart thimbles, thimbles shall be designed to ensure that any failures occur in a ductile manner and remain intact. 5.2 Dimensions Thimbles should conform to the relevant dimensions specified in Tables 2 and 3. NOTES: 1

Thimbles may be supplied with or without points.

Gussets may be required on thimbles with a size of 20 mm and greater, to reduce deformation.

Thimbles may be supplied in the open condition.

Where a thimble is used with a steel wire rope that has a capacity greater than 6 × 36 or 6 × 19 IWRC 1770 MPa, it may be necessary for the thimble to be modified to provide adequate resistance to deformation (see Clause 6.1).

The dimensions listed in Table 2 are provided as a recommendation and are not intended to preclude thimbles with minor variances, provided they perform as intended by this Standard.

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AS1138 - 2008

TABLE 2 DIMENSIONS OF ORDINARY, REEVING, AND CONTIGUOUS THIMBLES millimetres B

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Nominal size of thimble

Ordinary thimbles

Reeving thimbles

Min.

Max.

Min.

Max.

Min.

Max.

Min.

Max.

2.5d

3.8d

6.0d

7.5d

8.0d

1.55d

0.45d

1.07d

See Note

8 9 10

20 23 25

24 27 30

31 35 38

48 54 60

60 68 75

64 72 80

12 13 15

3.6 4.1 4.5

9 10 11

4.4 4.9 5.5

11 12 13

28 30 33

33 36 39

42 46 50

66 72 78

83 90 98

88 96 104

17 18 20

5.0 5.4 5.9

12 13 14

6.0 6.6 7.1

14 16 18

35 40 45

42 48 54

54 61 69

84 96 108

105 120 135

112 128 144

21 24 27

6.3 7.2 8.1

15 18 20

7.7 8.8 9.9

20 22 24

50 55 60

60 66 72

76 84 92

120 132 144

150 165 180

160 176 192

31 34 37

9.0 9.9 11

22 24 26

11 12 13

26 28 32

65 70 80

78 84 96

99 107 122

156 168 192

195 210 240

208 224 256

40 43 49

12 13 15

28 30 35

14 15 24

36 40 44

90 100 110

108 120 132

137 152 168

216 240 264

270 300 330

288 320 352

55 62 68

17 18 20

39 43 48

27 30 33

48 52 56

120 130 140

144 156 168

183 198 213

288 312 336

360 390 420

384 416 448

74 80 86

22 24 26

52 56 60

36 39 42

150

180

228

360

450

480

NOTE: For d≤28 mm, Jmax = 0.55d nominal. For d>28 mm, Jmax = 0.75d nominal.

5.3 Holes The connecting hole in solid heart thimbles shall be machined normal to the plane of the rope groove of the thimble and centred on the line of force. NOTE: Solid heart thimbles may have a lightening hole or recess toward the point of the thimble, provided the strength of the thimble complies with this Standard.

5.4 Bosses Bosses may be provided on both sides of solid heart thimbles. 5.5 Heat treatment Forged thimbles shall be normalized. Thimbles manufactured by other methods may require heat treatment to minimize residual stresses.

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AS1138 - 2008

TABLE 3

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DIMENSIONS OF SOLID HEART THIMBLES Nominal size of thimble

Min.

Max.

Min.

3.3d

1.55d

0.45d

1.07d

0.5d

8 9 10

27 30 33

56 63 70

16 18 20

12 13 15

3.6 4.1 4.5

9 10 11

4.0 4.5 5.0

11 12 13

37 40 43

77 84 91

22 24 26

17 18 20

5.0 5.4 5.9

12 13 14

5.5 6.0 6.5

14 16 18

47 53 60

98 112 126

28 32 36

21 24 27

6.3 7.2 8.1

15 18 20

7.0 8.0 9.0

20 22 24

66 73 80

140 154 168

40 44 48

31 34 37

9.0 9.9 11

22 24 26

10 11 12

26 28 32

86 93 106

182 196 224

52 56 64

40 43 49

12 13 15

28 30 35

13 14 16

36 40 44

119 132 146

252 280 308

72 80 88

55 62 68

17 18 20

39 43 48

18 20 22

48 52 56

159 172 185

336 364 392

96 104 112

74 80 86

22 24 26

52 56 60

24 26 28

198

420

120

5.6 Defects and finish Thimbles shall be free from any roughness, sharp edges, or other defects that may impair the strength or service life of the thimble, or cause a reduction of strength or service life of wire rope, or create a handling hazard. NOTE: Where a thimble is to be opened and closed after manufacture to allow for the insertion of another component, care has to be exercised to avoid any surface cracking that may impair its strength or service life.

5.7 Surface finish The surface finish shall be one of the following: (a)

Self-coloured (see Clause 3.3).

(b)

Hot-dip galvanized coating complying with AS/NZS 4680 or AS/NZS 4791, as applicable.

(c)

Class A1, Class A2, or Class B phosphate coating complying with AS 1627.6.

(d)

Fe/Zn 12c electroplated zinc coating complying with AS 1789.

(e)

Fe/Cd 12c electroplated cadmium coating complying with ISO 2082.

(f)

Painted coatings. NOTE: AS 1627.0 gives guidance for preparing steel surfaces for painting.

(g)

Any other surface finish that does not cause a degradation of the mechanical properties of the finished product.

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AS1138 - 2008

6 MECHANICAL PROPERTIES 6.1 General The mechanical properties specified in Clauses 6.2 to 6.4 shall be verified by testing under the conditions specified in Appendix C. 6.2 Strength Each thimble shall be capable of supporting a test load equal to the relevant minimum breaking force of the rope, while remaining intact and retaining the test rope in the groove of the thimble. The minimum breaking force shall be as follows: (a) For standard capacity ropes, that is 6 × 36 or 6 × 19 IWRC 1770 MPa, as specified in Column 2 of Table 4.

(b)

For higher capacity ropes, to be advised by the manufacturer.

6.3 Deformation Each thimble shall be capable of supporting a test load equal to 0.27 times the relevant minimum breaking force of test rope as specified in Column 3 of Table 4, without dimension A in Figure 3 being reduced by more than 15%. Accessed by Wesfarmers Industrial and Safety Ltd on 09 Mar 2018 (Document currency not guaranteed when printed)

6.4 Ductility Except for cast solid heart thimbles, any type test failure should occur in a ductile manner. 7 MARKING Thimbles may be marked. Any indented marking shall not have sharp edges and the depth and location of any marks shall not reduce the strength of the thimble. 8 TESTING OF MECHANICAL PROPERTIES Compliance of each design with the requirements of Clause 6 shall be demonstrated in accordance with Appendix C. NOTES: 1

The test of each design is known as the type test, which determines the adequacy of the design for achieving the required performance.

Each change in manufacturing process, grade of material, design, and size necessitates separate type testing, to demonstrate compliance with the requirements of Clause 6.

In addition to type testing, effective quality control necessitates systematic testing of each lot or batch to ensure continuing compliance with the requirements of Clause 6.

Means for demonstrating compliance with this Standard are given in Appendix D.

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AS1138 - 2008

TABLE 4

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TEST FORCES 1

Nominal size of thimble

Minimum breaking force of test rope (see Note)

Deformation force (see Clause 6.2)

8 9 10

40.2 51.1 63.1

10.9 13.8 17.0

11 12 13

76.3 90.8 107

20.6 24.5 28.9

14 16 18

124 161 204

33.5 43.5 55.1

20 22 24

252 305 363

68.0 82.4 98.0

26 28 32

426 494 646

115 133 174

36 40 44

817 1010 1220

221 273 329

48 52 56

1450 1710 1980

392 462 535

2270

613

NOTE: The values for minimum breaking force of test rope in Column 2 are specified in AS 3569 for Grade 1770, galvanized or natural, round strand, equal lay, steel wire rope.

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AS 1353.1—1997 Reconfirmed 2014

Australian Standard® Flat synthetic-webbing slings Part 1: Product specification

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AS 1353.1—1997

Where the webbing has been woven on a shuttleless loom, lock threads of maximum runproof construction shall have been embedded in the webbing to stop it from unravelling in the event of a thread being damaged. NOTE: For positive identification, the sling manufacturer should ensure that the rolls of webbing used in the manufacture of synthetic-webbing flat slings are marked with the webbing manufacturer’s name or trade mark and the batch identification.

4.2

Protection The webbing shall minimize any ingress of harmful particles, by—

(a)

heat setting (i.e. thermofixing);

(b)

having a protective covering; or

(c)

being woven in a relatively impenetrable type of construction.

4.3 Thread Thread used to sew webbing and to attach sleeves and labels shall be of the same type of high-tenacity continuous-multifilament fibre as that of the webbing, so that it will be as resistant to fibre degradation as is the fibre in the webbing. 5

DESIGN AND MANUFACTURE

5.1

Construction Slings may be of any of the constructions defined in Clause 3.2.

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5.2 Multileg slings The legs of multileg slings are normally interconnected by one of the following arrangements: (a)

For two-leg slings, by attaching each of the legs directly to a master link.

(b)

For three-leg or four-leg slings, by using a master link assembly with two intermediate links and attaching two of the sling legs directly to one of the intermediate links and the other sling leg or two sling legs directly to the other intermediate link.

5.3 Overcrowding To prevent overcrowding of multileg slings, each link that supports two or more legs in a sling shall be of an adequate size that will allow these legs to support a load with an included angle between the legs of 60°, without the legs contacting each other. 5.4

Dimensions

5.4.1 Width The width of slings, measured without tension in the webbing, shall be not less than 25 mm and shall be expressed in millimetres. Actual widths should not differ from the nominal width by more than the following: (a)

For widths of not more than 100 mm

. . . . . . . . . . . . . . . . . . . . . . . ±10 percent.

(b)

For widths of more than 100 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . ±8 percent.

5.4.2 Effective length The effective length (see Clause 3.3) of slings of synthetic fibre shall be measured more than 10 min after the release of any forces and shall be expressed in metres. Such a measured length shall have an accuracy of ±3 percent of the nominal length. 5.4.3

Inside length of eyes The inside length of eyes shall be—

(a)

for webbing widths of not less than 25 mm nor more than 33 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . not less than 100 mm;

(b)

for webbing widths of more than 33 mm but not more than 150 mm . . . . . . . . . . . . . . . . . . . not less than 3.0 times the webbing width; and

(c)

for webbing widths of more than 150 mm the webbing width.

. . . . . . . . . . . . not less than 2.5 times

The inside length of eyes in webbing fitted around a round cross-sectional part of an end fitting shall be not less than 2.5 times the diameter of the part. COPYRIGHT

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AS 1353.1—1997

5.5 Sewing The sewing shall provide an even distribution of the load across the breadth of the webbing without damaging the selvedge. The beginning and the end of sewing threads shall be back sewn for not less than 25 mm. Sewing shall be carried out by a lock-stitch machine or similarly suitable machine, and shall be evenly embedded into both surfaces of the webbing joint. Lock sewing shall not be visible from either side of the joint. There shall be not less than 25 mm backtrack to lock the sewing of any broken thread. The sewing method should minimize any loss of flexibility. 5.6 Sewing faults There shall be not more than one fault in the sewing, including an incomplete stitch, in any 125 mm length. 5.7 Needle temperature There shall be no damage caused by excessive temperature of the sewing needle. 5.8 Ends Heat-sealed ends shall not be oversewn, unless either the thread is protected from abrasion or the form of the heat seal cannot cause damage to the thread. Soft-cut ends may be oversewn.

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5.9 Protective sleeves Any protective sleeves used on slings, other than those fully bonded to the sling to prevent the ingress of harmful particles, shall meet the following requirements: (a)

Not sewn to sling If not sewn to the sling, protective sleeves shall be capable of being moved to enable the full length of the load-bearing component of the sling to be inspected.

(b)

Sewn to sling If sewn to the sling, protective sleeves— (i)

shall be of the same fibre material and have the same mechanical properties as the sling; and

(ii)

shall be fully sewn to the sling around the outer edges of the sleeve, to minimize the ingress of material between the sling and the sleeve.

Aramid polyamide webbing shall be sheathed or coated, to provide protection from sunlight and other ultraviolet sources. 5.10

Termination Slings may have the types of termination defined in Clause 3.4.

Two end fittings on a sling need not be identical. If a sling is designed for choked slinging, one fitting should be able to pass through the other fitting. Any end fittings shall have a working load limit of not less than that of the sling and shall comply with AS 3585 or AS 3776. The interface between the webbing and the end fitting shall be such that the strength of the sling leg will not be compromised by either overcrowding or the interface contact area. 6

MECHANICAL PROPERTIES

6.1 Webbing The webbing component of each sling shall be capable of withstanding a test force equivalent to T times the working load limit of the sling under the conditions specified in Appendix B, where T = 9.4 for nylon fibres and T = 8 for other fibres. NOTES: 1

The test force is generally referred to as the minimum breaking strength.

The higher factor for nylon fibres is to allow for a 15 percent reduction of strength when wet by water.

6.2 End fittings Clause 5.10 requires any end fittings to comply with AS 3585 or AS 3776, each of which includes requirements for mechanical properties.

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AS 1353.1—1997

6.3 Stitching The stitching shall be capable of withstanding the load that will cause failure of the sling under the conditions specified in Appendix B. 7

MARKING

7.1

Information

7.1.1 Mandatory information:

Each sling shall be permanently and legibly marked with the following

(a)

Working load limit.

(b)

SWL for various lifting configurations. The SWL of multileg slings shall be stated on the tag attached to the master link.

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NOTE: Where multileg sling assemblies are configured, ensure that there is no confusion between the working load limit of each leg with the SWL of the whole assembly. Also, refer to AS 1353.2.

(c)

Fibre material (e.g. nylon, polyester, polypropylene or aramid polyamide, as applicable).

(d)

Month and year of manufacture of the sling.

(e)

Identification marking to correlate the sling to a test certificate or batch number.

(f)

Manufacturer’s identification. NOTE: In any lifting or handling system that consists of components of different capacities, it is dangerous for each of these components to be tagged with its different capacity. A tag specifically marked for a higher capacity component could inadvertently be understood to refer to the complete lifting system.

The following list of precautionary warnings should also be provided:

7.1.2

Optional

(a)

Consult sling manufacturer or supplier for configurations not shown on the sling tag a relevant load chart.

(b)

Do not use sling if tag is removed.

(c)

Inspect sling for damage before each use.

(d)

Do not use sling if there is any sign of cut cover, snagging, heat or chemical damage, excessive wear, damaged seams, any other defects, or presence of grit, abrasive materials or other deleterious matter.

(e)

Do not tie knots in sling.

(f)

Protect sling from sharp edges of load.

(g)

Do not expose sling to temperatures above . . .

NOTE: Insert a safe maximum temperature. Information on safe temperatures is given under selection of material in AS 1353.2.

(h)

Do not allow abrasive or other damaging grit to penetrate the fibres.

(i)

Consult with manufacturer’s recommendations before immersing a sling in a chemical solution.

(j)

Keep away from . . . NOTE: Insert ‘acids’, ‘alkalis’, or ‘phenolic compounds’, as applicable. NOTES: 1

A typical label is shown in Figure 3.

Manufacturers making a statement of compliance with this Standard on a product, packaging or promotional material related to that product are advised to ensure that such compliance is capable of being verified. COPYRIGHT

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AS 1353.1—1997

The marking required by Clause 7.1 shall be given—

7.2

Means

(a)

for single-leg slings, on a label of a suitable material that is permanently attached to the webbing of the sling by sewing; and

(b)

for multileg slings, on a durable and corrosion-resistant tag that is permanently affixed to the master link.

7.3 Colour The colour of the label on the sling leg shall be used to identify the fibre material, using the following colour code: Webbing material Nylon Polyester Polypropylene Aramid polyamide

Colour Green Blue Brown Yellow

Where the colour of the sling leg is used to identify its WLL, the following colour code shall be used:

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Working load limit, t

Colour

1 2 3 4

Violet Green Yellow Grey

5 6 8 ≥ 10

Red Brown Blue Orange

8 TESTING OF MECHANICAL PROPERTIES requirements of Clause 6 shall be demonstrated.

Compliance of each design with the

NOTES:

The test of each design is known as the type test, which determines the adequacy of the design for achieving the required performance.

Each change in manufacturing process, grade of material, design, end fittings and size other than length necessitates separate type testing, to demonstrate compliance with the requirements of Clause 6.

Where sewing is manually controlled, the production from each sewing machinist should be tested.

In addition to type testing, effective quality control necessitates systematic testing of each lot or batch to ensure continuing compliance with the requirements of Clause 6. Such a lot may include slings that vary only in length, but similar slings produced by different machinists may be considered to be in different lots.

Methods for demonstrating compliance with this Standard are given in Appendix C.

PROOF TESTING

9.1 Proof loading Each sling shall be subjected to a proof force that is not less than [2 × 9.81 × (WLL, in tonnes)] kN applied under the conditions specified in Appendix B. COPYRIGHT

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AS 1353.1—1997

The sling shall—

9.2

Requirements

(a)

withstand the application of the proof force, without sustaining damage that could affect its intended function or safety; and

(b)

after testing, be free from any deleterious permanent set or visible defects.

A competent person (see Clause 3.1) shall be satisfied that the sling complies with these requirements.

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9.3 Test certificate The proof testing shall be recorded on a test certificate, which shall bear the following information: (a)

Construction.

(b)

Type of terminations.

(c)

Sling material (including webbing, thread and any end fittings).

(d)

Width.

(e)

Effective length.

(f)

For single-leg slings or endless slings, working load limit.

(g)

For multileg slings, working load limit or safe working load.

(h)

Proof force.

(i)

Date of proof test.

(j)

Number tested.

(k)

Identification marking correlating with the slings.

(l)

A declaration that the slings comply with this Standard, i.e. AS 1353.1.

(m)

Name and address of the manufacturer or supplier.

(n)

Name and address of the testing establishment.

(o)

Name of the signatory.

(p)

Type of certificate (e.g. NATA, certifying authority, supplier).

NOTE: The manufacturer or supplier should retain the original test certificate for not less than 10 years.

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AS 1353.2—1997

Reconfirmed 2014

Australian Standard Flat synthetic-webbing slings Part 2: Care and use

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AS 1353.2—1997

TABLE

SAFE WORKING LOADS UNDER GENERAL CONDITIONS OF USE FOR SINGLE-PART SINGLE-LEG SLINGS

tonnes

Safe working load (see Note) Basket hitch and 2-, 3-, and 4-leg slings Straight lift L=1

Choked lift L = 0.8

1 2 3

0.8 1.6 2.4

4 5 6

8 10 12

β = 60° L = 1.73

β = 90° L = 1.41

2 4 6

1.7 3.4 5.1

1.4 2.8 4.2

1 2 3

3.2 4.0 4.8

8 10 12

6.9 8.6 10.3

5.6 7.0 8.4

4 5 6

6.4 8.0 9.6

16 20 24

13.8 17.3 20.7

11.2 14.1 16.9

8 10 12

Parallel L=2

β = 120° L=1

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WLL in basic configuration

NOTE: Safe working load = L × WLL L

Loading factor

Included angle between the legs

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AS 1353.2—1997

TABLE

SAFE WORKING LOADS UNDER GENERAL CONDITIONS OF USE FOR TWO-LEG, THREE-LEG AND FOUR-LEG SLINGS tonnes 1

Direct loaded

6 Choke hitch

Single wrap

Double wrap

0° to 45°

0° to 60°

Method of loading

Included angle β

0° to 60°

Loading factor, L

1.73

90° 1.41

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WLL in basic configuration

120° 1

1.38

Safe working load

1 2 3

1.7 3.4 5.1

1.4 2.8 4.2

1 2 3

1.3 2.7 4.1

4 5 6

6.9 8.6 10.3

5.6 7.0 8.4

4 5 6

5.5 6.9 8.2

8 10 12

13.8 17.3 20.7

11.2 14.1 16.9

8 10 12

11.0 13.8 16.5

Bullivants | Page 26 of 692

AS 1353.2—1997

8 STORAGE to slings.

Proper storage is essential for the prevention of deterioration and damage

Wet slings shall be allowed to dry naturally before being stored. Under no circumstances should slings be heated or otherwise force dried (see also Item (e) of Clause 6.2).

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Slings shall be stored in locations that have the following conditions: (a)

Clean and free from dirt and grit.

(b)

Dry and ventilated, to prevent condensation (i.e. never in receptacles that do not permit air circulation).

(c)

Off the ground, off the floor, and without contact with any surface that may corrode during use; preferably on gratings, racks, stands or special coil pegs.

(d)

Away from the following:

(i)

Direct sunlight and ultraviolet rays.

(ii)

Sources of heat (e.g. steam pipes, furnaces).

(iii)

Sparks from any source.

(iv)

Chemically degrading atmospheres, including damaging fumes.

(v)

Chemically containers.

(vi)

Locations where mechanical damage is likely to occur, such as on or underneath racks containing heavy objects that could inadvertently damage the slings.

degrading materials, including

liquids that may leak from

INSPECTION

9.1 Signs of damage The following signs of damage should be looked for during inspections, particularly during periodic inspections (see also Figure 3): (a)

External wear External wear caused by dragging over rough surfaces causes an opening out of surface fibres (with a furry appearance). This is the most noticeable cause of weakness, particularly when a sling is being compared with a new sling. The outer faces of the webbing may become so worn that yarns in the weave are severed. The label may become damaged.

(b)

Local abrasion Any substantial local abrasion must be viewed critically. Local abrasion will be caused by movement over sharp edges while the sling is under tension, which will result in a loss of strength.

(c)

Cuts and contusions Cuts and contusions may be indicated by local loosening of the yarns.

(d)

Internal wear Internal wear will be caused by repeated flexing, particularly when particles of grit have penetrated into the fibres. Any thickening of the sling or presence of grit or dirt may indicate internal wear.

(e)

Damage to protective coating or sleeve Any damage to a protective coating or sleeve can allow abrasive grit an easier access to the sling.

(f)

Damage from high temperatures High temperatures can result from a hot environment, radiation or friction. High enough temperatures will cause fusing or shrinkage of synthetic webbing. Fusion is able to occur at temperatures approximately equal to the melting point of the polymer from which the fibres have been made. The melting point of polypropylene is 165°C. The melting points of nylon or polyester are in the range 260°C to 265°C. Aramid polyamide does not melt.

rupturing

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AS 1353.2—1997

(g)

Sunlight degradation Prolonged exposure to ultraviolet radiation (including sunlight) of any textile fibres will weaken the fibres. Degradation may be indicated by a hairy appearance of fibres.

(h)

Chemical attack Chemical attack is usually indicated by local weakening or softening of the webbing material, allowing the surface fibres to be plucked or rubbed off. In some cases it may cause some stiffening of the sling. In extreme cases surface fibres are reduced to powder.

(i)

Label damage

(j)

Deterioration of stitching

(k)

Damage of any eyes

(l)

Damage at the connection to any terminal attachment

(m)

Damage to any end fittings NOTE: Some samples demonstrating extreme damage to flat synthetic-webbing slings are shown in Figure 3.

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9.2 Before each use Every time a sling is to be used, the user shall be satisfied that the sling does not show any signs of damage that could affect its safe use. Particular attention should be given to circumstances, locations and atmospheres that are likely to result in accelerated damage. Slings shall be withdrawn from service immediately they sustain any of the following faults: (a)

Any of the discard criteria listed in Clause 11 is observed.

(b)

A dangerous condition of the sling is suspected.

(c)

The label is illegible or missing.

(d)

The cover or sewn sleeve has been damaged.

(e)

The stitching has been damaged.

(f)

A protective coating has been damaged.

(g)

An end fitting or a coupling has been damaged.

9.3 Evaluation When a sling has been withdrawn from service because of any doubt about its condition, its safety may be evaluated by a competent person. The competent person may approve of the sling being returned to service, if the concern is considered to not affect the safety of the sling. The competent person may recommend repair of the sling, provided the sling can be identified and it is considered that the load-bearing fibres have not been damaged. 9.4

Periodic inspection

9.4.1 General Slings shall be inspected by a competent person at intervals of service of not more than three months, and where conditions are severe at shorter intervals. The inspection for any signs of damage shall cover all surfaces along the full length of the slings. 9.4.2 Testing Where slings are in frequent service, at intervals not exceeding 12 months of service, the sling considered to have the most deterioration shall be subjected to a destruction test to determine its breaking force. If the sling is found to have lost 10 percent or more of its minimum breaking strength, the next worst sling shall be similarly tested. This process shall be repeated until a sling is found that has not lost 10 percent or more of its minium breaking strength. Any remaining slings may then be deemed to be acceptable for use.

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AS 1353.2—1997

9.5 Inspection records For each sling, a record of every evaluation by a competent person and the details of periodic inspections shall be kept for the life of the sling. The record shall include the date of purchase, the date of introduction to service and general details of the service. 10 CLEANING If a sling requires cleaning, refer to the manufacturer or supplier for suitable cleaning methods.

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11 DISCARD CRITERIA Slings shall be immediately discarded when they are found to have any of the following faults: (a)

The label for the sling is missing or is illegible, and the sling cannot be positively identified.

(b)

Whenever a sling has lost 10 percent or more of its minimum breaking strength. If there is any doubt as to the strength of a sling, a method of establishing its loss of strength is given by Clause 9.4.2.

(c)

Any of the load-bearing fibres are damaged. Any damage to a cover indicates potential damage to the load-bearing webbing. Such damage may be in the form of surface chafe or cuts in the cover. Any cuts in the cover should raise serious doubts as to the integrity of the load bearing webbing. Fibres of a protective cover that are fused or glazed indicates that the sling has been excessively heated (e.g. by friction in a choke hitch, by externally applied heat).

(d)

Chemicals have caused any damage (e.g. local weakening, softness of the cover, flaking of surface fibres). In such cases, damage to the load-bearing webbing should be assumed, particularly where it is known or suspected that— (i)

a nylon sling has come into contact with an acid solution;

(ii)

a polyester sling has come into contact with an alkaline solution; or

(iii)

a polypropylene sling has come into contact with an organic solvent (e.g. wet paint, coal tar, paint-stripping mixtures).

(e)

Any coupling components or fittings are distorted, cracked, fractured or excessively worn or corroded.

(f)

If any other dangerous condition is confirmed.

REPAIRS

Slings having any of the faults listed in Clause 11 shall be discarded.

This Standard does not permit repairs to load-bearing webbing of a sling, but manufacturers may replace labels and repair removable covers. Any repaired slings shall be proof loaded.

Bullivants | Page 29 of 692

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AS 1353.2—1997

(a) Surface wear due to abrasion, which is evident by the furry surface

FIGURE 3

(in part) EXAMPLES DEMONSTRATING EXTREME DAMAGE TO FLAT SYNTHETIC-WEBBING SLINGS

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AS 1353.2—1997

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(b) Examples of load-bearing fibres that have been cut

(d) The use of hooks that are too narrow has damaged the eye of the sling

NOTE: See Clause 10 for specific requirements for discard.

FIGURE 3 (in part) EXAMPLES DEMONSTRATING EXTREME DAMAGE TO FLAT SYNTHETIC-WEBBING SLINGS

Note, Refer to Bullivants Work Instruction: BV-QMS-WI-18 Inspection of Synthetic products Marked with Permanent Marker Found HERE

Bullivants | Page 31 of 692

FOR REFERENCE ONLY This standard has been withdrawn for revision. Bullivants | Page 32 of 692

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FOR REFERENCE ONLY This standard has been withdrawn for revision

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AS 1418.1:2021

Cranes, hoists and winches Part 1: General requirements

Originated as part of AS CB2-1938. Revised and redesignated as AS 1418.1:1977. Previous edition 2002. Fifth edition 2021.

© Standards Australia Limited 2021 All rights are reserved. No part of this work may be reproduce or copied in any form or by any means, electronic or mechanical, including phot copying, without the written permission of the publisher, unless otherwise permitted under the Copyright Act 1968 (Cth).

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AS 1418.1:2021

4 Craneloads 4.1 Scope of section

This Section specifies the requirements for the determination of crane load and Joa� combinations to be used in the design of cranes and their supporting structures. J NOTE This Section supersedes Section 4 Crane loads, and Clauses 7.4 to 7.9, of AS 1418.1-2002.

4.2 Determination of crane loads

The determination of loads shall be supplemented by the requirements of other par s of the AS 1418 · I series, as applicable. Methods for calculating crane loads and their combinations for the purpose of designing crane structures and mechanisms and the method for determining the rigid body stability of cranes using partial load factors shall be in accordance with AS 5221.1. "ON

4.3 Wind loads

Methods for load calculating wind loads service conditions (which included in the load and combinations statedforinin ASservice 5221.1 and and out usedoffor proof of competence suchare as those given in AS 5224 for structural components of cranes) shall be in accordance with AS 5222. In comparison with AS 1170.1, which is largely concerned with wind load on buildings in specified locations, AS provides a simplified method for determining the wind loads on cranes and components commonly employed on cranes

4.4 Seismic loads The general methods for calculating seismic loads to be used in crane load combinations shall be in accordance with either (a) ISO 11031 and combined in accordance with AS 5221; or

( b) AS 1170.4, combined with other crane loads calculated in accordance with AS 5221, and combined in accordance with AS 1170.1.

NOTE At this stage relevant seismic maps for Australia compatible with ISO 11031 have not been developed.

Design of craneand supporting structures

Methods for designing steel structures used in cranes shall be in accordance with AS 5224. NOTE This Section supersedes Section 5 Design of crane structure of AS 1418.1-2002.

The effect of loads, applied by the crane to its supporting structure shall be taken into account. Crane runways shall be designed in accordance with AS 1418.18.

6 Stability

Stability of cranes shall be in accordance with the requirements of AS 5225. Additional methods for establishing stability against overturning using partial load factors are specified in AS, 5221. Anchoring devices for cranes and crane parts for in service and out of service conditions shall be in accordance with AS 5226.1.

NOTE This Section supersedes the stability requirements referenced in Section 6 Stability of AS 1418.1-2002 and Clause 6.4 Safety against drifting of AS 1418.1-2002. © Standards Australia Limited 2021 Bullivants | Page 40 of 692

AS 1418.1:2021

Repairs shall be carried out in accordance with AS 2550.1.

13 Inspection and testing Test, inspections and procedures for verifying the conformance of a crane wit� its operational specifications and its capability to lift rated loads shall be carried out in accordance wtth the applicable parts of AS 1418. This requirement shall apply prior to first use following manufacture, and after modification or repair of the load bearing structure or components of an individual er I ne. NOTE This Section supersedes Section 13 Inspection and testing of AS 1418.1-2002.

14 Marking 14.1 Scope of section I

This Section specifies the requirements for marking of the crane and associated equipment.

14.2

General

Labels for the identification (marking) and the operation of cranes shall be in accordance with AS 5235.1, in addition to AS 5233.1, which specifies general requirements for marking of controls. NOTE This Section supersedes Section 14 Marking of AS 1418.1-2002.

14.3

Marking

The crane shall be marked in accordance with the marking requirements specified in the applicable part of the AS 1418 series. The crane and crane subassemblies shall be marked legibly and permanently with the manufacturer's traceable marking. Independent hoisting mechanisms shall include marking for the rated capacity.

15 Operating environment 15.1

General

This '- Section specifies the information that shall be taken into account when selecting materials and equipment to be used in the design of the crane so that the crane is capable of rated pe formance (a) under the normal indoor service conditions as specified in Clause 15.2.1; ( b) under the normal outdoor service conditions as specified in Clause 15.3.1; (c) under special service conditions, examples of which are given in "'"".......,......_.......,c.-..w...... and .15...3..2. for indoor and outdoor services respectively, subject to the purchaser advising the manufacturer of the specified service condition applicable; and

(d) in hazardous environments. as specified in Clause 15.4. subject to the purchaser advising the manufacturer of the hazardous service condition applicable.

AS 1418.2—1997

Australian Standard® Cranes (including hoists and winches) Part 2: Serial hoists and winches

PUBLISHED BY STANDARDS AUSTRALIA (STANDARDS ASSOCIATION OF AUSTRALIA) 1 THE CRESCENT, HOMEBUSH, NSW 2140 ISBN 0 7337 0889 7

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AS 1418.2 — 1997

1.7

COMPONENTS

1.7.1 General Components used to connect and assemble load sustaining parts shall be designed and fitted with positive means to prevent them developing conditions which may lead to reduced safety. 1.7.2

Hookblock

1.7.2.1 Hooks Hooks should comply with AS 3777, ISO 4779, ISO 7597, BS 2903, DIN 15400, or JIS B 2803, or shall have strength and deflection characteristics not less than those specified therein for a hook of the same rated capacity. Hooks shall have provisions for the fitting of safety catches. Safety catches shall be provided for all hooks which are intended to support personnel. Hooks shall be secured by suitable means. Where a hook is supplied with a nut, the nut shall be fully secured. 1.7.2.2

Crossheads for hooks

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1.7.2.3 Suspension requirements:

Crossheads shall be of single-piece steel construction.

Suspension,

where

fitted, shall

comply

with

the

following

(a)

Bottom suspension—the bottom suspension shall have a bearing which is capable of swivelling with the safe working load applied.

(b)

Top suspension —where the top suspension is required to swivel, it shall be fitted with a bearing which may incorporate friction washers. The top connecting hook of a hook suspended hoist shall be fitted with a safety catch or equivalent.

1.7.3

Pawl and ratchet

(a)

Material shall provide the required wear resistance and toughness to comply with the requirements for the life of the equipment. With steel this is normally achieved by hardening and tempering. Where cast iron is used, it shall be spheroidal graphite complying with AS 1831.

(b)

The relative width and positioning of the ratchet wheel and the pawl shall be such as will ensure full engagement irrespective of wear on the friction faces of the brake.

(c)

Pawls shall either be spring-loaded or have equally effective means to ensure positive engagement with the ratchet wheel. Helical springs, where used, shall be designed in accordance with BS 1726.1 and provision shall be made for positive retention to prevent displacement by bowing.

(d)

The pawl shall be positioned so that engagement with the ratchet wheel is effected by gravity should its operating mechanism fail, unless an additional automatic holding device is fitted. Other devices may be used provided they achieve the same purpose. The pawl shall not be capable of rotating beyond its effective operating range.

(e)

Unless materials with inherent lubricating properties are used, provision shall be made for lubrication of the pawl pin.

Where a pawl is fitted, the following requirements shall apply:

1.7.4 Mountings and attachment Appropriate provision supporting medium shall be made on the serial hoist.

for attachment

to the

1.8 ELECTRICAL EQUIPMENT AND CONTROLS Electrical equipment and controls incorporated in serial hoists and winches shall generally comply with the requirements for electrical equipment and controls of AS 1418.1, except that deviations to motor dimensions are allowable to suit the particular arrangements of the manufacturer. Where pendent cords are used, they shall be yoked or otherwise coupled together at the lower end. COPYRIGHT

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AS 1418.2 — 1997

1.9 PNEUMATIC EQUIPMENT AND CONTROLS Pneumatic equipment and controls incorporated in serial hoists and winches shall comply with the requirements for pneumatic equipment and controls of AS 1418.1. Where pendent cords are used, they shall be yoked or otherwise coupled together at the lower end. 1.10

PERFORMANCE

1.10.1 Rating values The nominal magnitude of the various performance characteristics of the serial hoists or the winches should comply with the R 10 series of preferred numbers specified in AS 2752, i.e. the following values and multiples of 10 thereof should be used:

1.10.2

1.00

1.25

1.6

2.0

2.5

3.2

4.0

5.0

6.3

8.0

Load rating of serial hoists and winches

1.10.2.1 Hoisting The rated capacity, hoisting, shall be expressed in tonnes or, for values less than 1 t, in kilograms. 1.10.2.2

Haulage

The haulage capacity shall be expressed in kilonewtons.

1.10.3 Range of hoisting or haulage be expressed in metres.

The nominal range of hoisting or haulage shall

1.10.4 Working speeds For power-operated serial hoists and winches, the nominal working speeds shall be expressed in metres per minute. 1.11

TESTING

1.11.1 General The quality of design (as defined in AS/NZS ISO 8402) of each type model shall be verified by a type test (see Clause 1.11.2). The type test shall be conducted on one or more production units within the manufacturer’s specifications.

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NOTE: Drum winches are to be tested under the most adverse conditions of load for the particular design.

1.11.2 Type test Each type model of serial hoist or winch shall be subjected to the tests prescribed in Clause 1.11.3 for manually operated hoists and winches or Clause 1.11.4 for power-operated hoists and winches, except that a model manufactured to a purchaser’s design specification and produced only in limited quantities need not be subjected to all of the tests but shall be subjected to such alternative test(s) as specified by the designer. Where there is only one unit made or for a large serial hoist or winch, the type test may take the form of a commissioning test. Manually operated serial hoists and winches which have been subjected to type tests shall not be used or offered for use. 1.11.3 Type tests for manually operated serial hoists and winches operated serial hoists and winches shall be subjected to the following tests: (a)

Manually

A test load equal to the rated capacity shall be applied to the serial hoist or winch, and shall be hoisted or hauled for 30 cycles in a manner similar to that used in normal practice, through the test range of hoisting or haulage including the functioning of all operational devices. The test range shall be the design range of hoisting or hauling or 3 m, whichever is the lesser. Drum hoists shall be tested while the maximum number of layers of wire rope specified by the manufacturer is wrapped around the drum. COPYRIGHT

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AS 1418.2 — 1997

A serial hoist or winch shall be considered to have passed this test, if it hoists or hauls, arrests and sustains the various test loads in any working position within the range of hoisting or haulage without visible or measurable permanent distortion.

(b)

A test load equal to twice the rated capacity shall be applied to the serial hoist or winch, and shall be hoisted or hauled through a distance sufficient to rotate the slowest moving part through not less than one complete revolution, without any part or component of the serial hoist or winch showing signs of permanent distortion or the serial hoist or winch becoming inoperative.

(c)

A static load equal to 4 times the rated capacity shall be applied for 15 min to the serial hoist or winch without distortion which may result in the release of the test load.

1.11.4 Type test for power-operated serial hoists or winches Power-operated serial hoists or winches shall be subjected to a test load equal to 1.25 times the rated capacity and shall be operated for 30 cycles through the range of hoisting or through 3 m, whichever is the lesser. Drum hoists shall be tested while the maximum number of layers of wire rope specified by the manufacturer is wrapped around the drum. A serial hoist or winch shall be considered to have passed this test, if it hoists or hauls, arrests and sustains the various test loads in any working position within the range of hoisting or haulage without visible or measurable permanent distortion. 1.11.5 Operational test Every serial hoist and winch shall have applied to it a test load equal to the rated capacity. The test load shall be hoisted or hauled through a distance sufficient to rotate the slowest moving part of the serial hoist or winch through not less than one complete revolution for manually operated hoists and winches or not less than two complete revolutions for power-operated hoists and winches. This test shall include the functioning of all operational devices of the serial hoist or the winch. NOTE: For large serial hoists or winches, this test may take the form of a commissioning test.

The serial hoist or winch shall hoist or haul, arrest, and sustain the test load in any working position within the full range of hoisting or haulage without adverse effects on any component. Scaffolding hoists shall be subjected to a test load equal to 1.25 times the rated capacity. 1.12 MARKING The marking of each type of serial hoist and winch shall be as specified in the appropriate Section of this Standard.

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Marking shall be in plain English, and values shall be in SI units (see AS 1000). NOTE: Manufacturers making a statement of compliance with this Australian Standard on a product, packaging, or promotional material related to that product are advised to ensure that such compliance is capable of being verified.

1.13 TEST CERTIFICATE Where required by the purchaser or regulatory authority, a test certificate shall be provided, and shall contain the following information about each serial hoist or winch: (a)

Type model identification.

(b)

Serial number.

(c)

Description.

(d)

Classification of mechanism of serial hoist or winch where powered.

(e)

Rated capacity hoisting or hauling.

(f)

Test load applied. COPYRIGHT

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AS 1418.2 — 1997

2.3.6 Operation of lever chain hoist The load shall be moved by the operation of a lever and the direction of movement shall be determined by means of a positive ratchet arrangement. It shall be possible to change the direction of movement of the load chain without releasing the load. Means shall be provided to allow the operator to move slack chain quickly to its required position when the hoist is not under load, but such means shall not operate when the hoist is under load conditions. 2.3.7 Lever mechanism The lever mechanism shall comply with the requirements of Clause 1.11.5 without distortion. 2.3.8 Short-link load chain Short-link calibrated load chain shall comply with ISO 3077, DIN 5684, Part 1 to Part 3, or other equivalent Standard. The minimum safety factor based on the minimum breaking load shall be— (a)

for through-hardened chain with elongation greater than 10% . . . . . . . . . . 4:1; or

(b)

for through hardened chain with elongation greater than 5% and less than 10%, and for surface-hardened chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:1.

2.3.9 Roller chain Roller chain shall comply with AS 1532. The safety factor of the roller chain based on the minimum breaking load shall be not less than 5. NOTE: Roller type chains are relatively stiff in a direction transverse to the plane of rolling, and should not be used where they may be subjected to side loading.

2.3.10 Slack end anchorage The load chain anchorage, associated fittings and framework at the slack end, under no-load conditions, shall be capable of withstanding at the anchorage an operating effort of 750 N on a hand chain or 600 N on a lever mechanism without permanent distortion of the connecting pin. 2.3.11 Load chain terminal fittings Any fitting used to connect the load chain to a load-carrying anchorage shall be of a strength equivalent to that of the load chain. 2.3.12 Hand chain Hand chain shall have a minimum nominal size of 4.5 mm, shall be of smooth finish, and, when used with pocketed wheels, shall be calibrated. The hand chain shall be of adequate strength to withstand, without permanent deformation, a proof load of 3 times the maximum manual effort (see Table 1.6.2) required to hoist the rated capacity of the chain hoist. The length of the hand chain shall be as shown in AS 2549.

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2.3.13 Hand chain joining link The hand chain shall be joined without twist. The joining link shall be of the same material and dimensions as the hand chain, and may remain unwelded. 2.4 MARKING Each manually operated chain hoist shall be permanently and legibly marked with the following information:

(a)

Type model identification.

(b)

Serial or batch number.

(c)

Details of load chain as follows: (i)

Nominal size.

(ii)

Grade (quality).

(d)

Rated capacity hoisting and where applicable hauling.

(e)

Name or identification mark of the manufacturer of the chain hoist.

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AS 1418.2 — 1997

S E C T I O N 9.1

T R O LL E Y S

SCOPE OF SECTION This Section sets out requirements for trolleys.

It is supplementary to Section 1, but the requirements given in this Section take precedence over corresponding requirements in Section 1. 9.2 DESIGN Manually operated and power-operated trolleys shall be designed on the basis of the requirements as specified in this Standard for the respective serial hoist which it is intended to support. The trolley shall be designed so that it is safely retained on the monorail or runway in the event of— (a)

failure of a wheel or axle; or

(b)

excessive lateral forces.

The trolley with its suspended load shall run freely and the manual effort required for movement in the direction of travel as applied by the respective methods shall comply with Clause 1.6.2. 9.3

TESTING

9.3.1 Type test for integral manually operated or power-operated trolleys The integral trolley is automatically type tested when the attached hoist is subjected to loads specified in Clause 1.11.3, Items (a), (b), and (c) for a manually operated hoist, or Clause 1.11.4 for a power-operated hoist, except that the loaded trolley shall travel not less than 1 m along the monorail or runway. 9.3.2 Type test for other (non-integral) manually operated or power-operated trolleys The type test to be applied to other (non-integral) manual or power trolleys shall be as follows: (a)

A load as specified in Clause 1.11.3, Item (b) for a manually operated trolley or Clause 1.11.4 for a power-operated trolley, except that the loaded trolley shall travel not less than 1 m along the monorail or runway.

(b)

A static load as specified in Clause 1.11.3, Item (c).

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9.4 MARKING Each non-integral trolley shall be permanently marked with the following information: (a)

Type model identification (nominate if only for manually operated serial hoist).

(b)

Classification of mechanism (for power-operated trolleys only).

(c)

Rated capacity hoisting.

(d)

Name or identification mark of manufacturer of the trolley.

(e)

Range of monorail beam sizes which suit the trolley.

(f)

Power supply requirements where applicable. NOTE: For an integral trolley, the hoist marking is deemed to include the trolley.

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AS 1418.3—1997

(Incorporating Amendment Nos 1 and 2) Reconfirmed 2016 AS 1418.3

Australian Standard™ Cranes, hoists and winches Part 3: Bridge, gantry, portal (including container cranes) and jib cranes

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AS 1418.3—1997 For a girder, the following simplified equation for fundamental natural frequency may be used:

. . . 3.3.3(a)

where F = natural frequency, in hertz δ = vertical (or horizontal) deflection, in millimetres In the above equation, the value of δ for cantilever cranes shall include the flexure of the boom and the support posts. (b)

due to torsional vibration of the bridge structure.

3.3.4 Lateral forces on portal cranes Lateral forces on portal cranes due to oblique travel may be disregarded where the structure has sufficient inherent flexibility to prevent any effective transfer of such loads through the structure; however, lateral forces due to inertia shall be taken into account. 3.3.5

Camber

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Camber is not necessary to maintain serviceability. A2

3.3.6 Jib cranes The calculated deflection of jib cranes shall not exceed L/300 where L is the length of the jib plus length of freestanding post. Where the deflection is measured in situ by test methods, the permissible deflection may be increased as follows: (a)

Where the jib crane is mounted on a rigid support, 50% to allow for such effects as deformation of the anchoring bolts, baseplate, slew rings or other bearings and fasteners.

(b)

Where the jib crane is mounted on a flexible support, 100% to allow for such effects as deformation of the anchoring bolts, baseplate, slew rings or other bearings and fasteners, and deflection of the supporting structure.

3.4 SPAN TO WHEELBASE RATIO The ratio of span to wheelbase of the crane shall be not greater than 7.

S E C TIO N

STA BI L IT Y

Stability under in-service conditions and out-of-service conditions shall comply with AS 1418.1.

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AS 1418.3—1997

S E C TIO N 1 2 I N S P E C TI O N C OM M IS S ION IN G

AND

12.1 INSPECTION Prior to its being commissioned, the crane shall be inspected in accordance with AS 1418.1. 12.2 COMMISSIONING 12.2.1

General

The following tests shall be carried out during the commissioning of cranes: (a)

Pre-operational inspection and testing.

(b)

No-load operation and testing.

(c)

Load testing.

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The required performance of the crane should be agreed between the owner and supplier of the crane. Normally, the required performance will be lifting, lowering, and moving the maximum rated capacity at the rated speeds, smoothly with sufficient frequency to represent the normal operation of the crane. Safety procedures and precautions for each phase of inspection and testing should be agreed between the owner and supplier of the crane prior to commissioning. 12.2.2

Pre-operational inspection and testing

Pre-operational inspection and testing (including alignment checking) shall be carried out to ensure that all systems and items comply with the relevant drawings and specifications, and shall include the following: (a)

Checking of runway tracks for level and alignment.

(b)

Visual examination of all components, assemblies and drives and checking for correctness of fitting including tolerances, clearances, alignments, and adjustments.

(c)

Checking of greasing, oil levels, hydraulic systems, and pneumatic systems.

(d)

Visual examination of welded and bolted connections of structures and torque check all critical bolted connections.

(e)

Checking of all safety guards and their fittings.

(f)

Checking of details and correctness of electrical safety devices, circuits, earthing, insulation cubicles, and cabling.

12.2.3

No-load operation and testing

Following satisfactory inspection and testing in accordance with Clause 12.2.2, no-load operation and testing shall be carried out, and shall include the following: (a)

Cranes with pendant or cabin operating control

These shall be as follows:

(i)

The individual parts of the equipment shall be run under ‘manual’ control to check the proper operation of alarms and warning devices, the tracking of the crane, the operation of safety devices and the smooth acceleration and stopping of the crane.

(ii)

The crane shall be travelled and traversed over the full length of runways to check physical clearance from fixed obstructions.

(iii)

Pressure pipework shall be checked for leaks.

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AS 1418.3—1997

(b)

12.2.4

(iv)

Supply of lubricants shall be monitored.

(v)

Electrical circuits shall be proven to be functional. Any alterations shall be marked-up on the schematic diagram.

Cranes with remote operation or radio control After satisfactory operation of the individual parts of the crane in accordance with Item (a) above, the crane shall be tested in remote control mode in appropriate groups and then as a unit checking the correct sequencing of the equipment for all functions and for smooth hoisting, acceleration and retardation, until the reliability of the system at working temperatures has been demonstrated. Load testing

Following satisfactory no-load testing in accordance with Clause 12.2.3, load testing shall be carried out, and shall include the following: (a)

The maximum rated capacity shall be applied to the main hoist at the point causing maximum deflection. The maximum bridge deflection shall be checked and compared with the calculated deflection under rated capacity (as supplied by the crane supplier). The final deflection after removal of the load shall also be checked.

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NOTE: The deflection of the crane support system under rated capacity should also be taken into account.

(b)

Each hoist in turn shall be used to lift its rated capacity, and shall be checked for brake adjustment, hoisting speed and input current.

(c)

With maximum rated capacity applied to the main hoist, the crane travel and traverse shall be checked up to full speed to ensure that the load can be controlled satisfactorily, and hoist brake application when lowering on power failure shall be checked. The electrical system shall be checked for voltage drop and simultaneous operation of main hoist and travel under full load and acceleration.

(d)

Noise levels shall be checked, as required.

(e)

At the time of commissioning only, each hoist shall be checked with 110% of its rated capacity as in Item (b) above.

12.2.5

Reports

Accurate and complete reports of all testing shall be prepared. Such reports shall record all the information checked during the test including clearances, temperatures, voltages, currents, heat generation, noise levels, starting times, acceleration durations, stopping times, settings and other control set points.

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AS 1418.17—1996 Reconfirmed 2016

Australian Standard Cranes (including hoists and winches) Part 17: Design and construction of workboxes

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AS 1418.17—1996 S E C T IO N 4.1

I N S P E C TIO N

A N D

TESTING

GENERAL

4.1.1 Inspection and testing Each workbox shall be subjected to a construction and welding inspection and to load and stability tests by a competent person. 4.1.2 Care Load tests can be dangerous, as the strength of the workbox under test is not yet proven. The competent person supervising the tests shall ensure that only essential personnel are in the test area and that all necessary protection is provided and precautions are taken. 4.2 LOAD TEST The workbox to be tested shall be loaded with a distributed load not less than 2.2 times the safe working load and hoisted 3 m above the supporting surface, stopped and then lowered clear of the ground and held for not less than 2 min and sufficient additional time to allow visual examination. The workbox shall exhibit no signs of material distress, deformation, local buckling, weld failure or cracking at any location.

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4.3 STABILITY TEST The stability shall be tested in accordance with the conditions within Clause 2.5. When testing, the angle of the floor shall be less than 5°. The result shall be included in the test report. 4.4 CERTIFICATION Inspection certificates shall be provided for the workbox upon completion of construction and testing. The certificates shall record the workbox data-plate particulars and the test results. The test certificate may be combined with the construction inspection certificate. NOTE: A typical inspection and test certificate for a workbox is shown in Appendix C.

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AS 1418.18

Australian Standard™ Cranes (including hoists and winches) Part 18: Crane runways and monorails

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AS 1418.18—2001

S E C TI O N

D E SIG N

O F

RUN W A Y

G IR DE R S

5.1 GENERAL This Section sets out the requirements for structural design of runway girders and monorail beams constructed of structural steel. 5.2 FORMS OF CONSTRUCTION 5.2.1 General The runway girders may be designed as simply supported, continuous or cantilevered, as illustrated in Figure 5.2.1.

NOTE: Where possible, designers should ensure that the full maintenance implications of continuous spans investigated and agreed with those responsible for operations and maintenance.

are

FIGURE 5.2.1 FORMS OF CONSTRUCTION

5.2.2 Simply supported girders The girder span shall be taken as the distance between the points of application of the girder reactions. The bending moments and shear forces shall be determined by a procedure that allows the wheel load train to be positioned in a least favourable location that produces maximum load effects (moments or shears) at a particular section. 5.2.3 Continuous girders The girde r spa n shall be taken to be equal to the distance between the girder bearings. The bending moments and shear forces shall be determined by an elastic method of analysis. The loads shall be take n at their maximum or minimum value, as necessary, to obtain the least favourable load effects at any position on the girder. Loads in adjacent spans shall be positioned to obtain the worst load effects. Semi-continuous girders featuring pin connections at or near quarter points are not recommended as maintenance problems are usually encountered in these details.

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AS 1418.18—2001 5.2.4 Cantilevered girders The spa n of the cantilever shall be take n to be the distance between the centre of the bearing supports and the furthest possible location of the crane wheel at the free end. In computing the deflection at the outward wheel on the cantilever, the rotation of the structural members at the support shall be included. 5.3 APPLICATION OF CRANE LOADS 5.3.1 Placing the wheel train In the computation of be nding moments and shear forces, the wheel loads of one or more cranes shall be positioned in order to produce the most unfavourable effects. Where two or more cranes can traverse the runway girder span, the cranes shall be positioned as close as the uncompressed buffers permit. 5.3.2 Point of application of loads The point of application of the wheel loads shall be taken as follows: (a)

Vertical wheel load on heavy-duty I-section runway girders Consideration of this eccentricity in the design of light duty runways may be omitted. Vertical wheel loads in the design of heavy duty runways shall be assumed to be applied at a minimum distance from the centre-line of the web of:

L B e = + TE y 1000 k

. . . 5.3.2

where ey = design eccentricity in lateral sense, in millimetres L

= span of crane girder

BTE = effective railhead width as defined in AS 1418.1 k

= 8 for flat with concave head or corner radii OR

= 4 for flat head rails

Figure 5.3.2 illustrates the definition of the dimensions. Where girders are designed such that they can be laterally adjusted at supports by a suitable girder/column cap L L . connection, the term in the above equation may be taken as 1000 2000 (b)

Horizontal wheel loads on runway girders of top running cranes Horizontal wheel loads shall be assumed to be applied at the top flange of the runway beam for light duty runways. Horizontal wheel loads shall be assumed to be applied at the top of the crane rail for heavy duty runways.

(c)

Horizontal wheel loads on monorail runways The horizontal wheel loads shall be applied at the top surface of the bottom flange.

5.3.3 Torsion The torsional effects of the above wheel eccentricities shall be taken into account in the design of heavy duty crane runways. Such effects may be excluded from the design of light duty crane runways. The effects of Clauses 5.3.2(a) and 5.3.2(b) shall be added to obtain the maximum torque.

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AS 1418.18—2001 End stop impact forces shall be accommodated in the design of longitudinal bracing of the building structure or the crane runway system, or both.

FIGURE 5.10 LATTICE GIRDER DETAILS

5.12 MONORAIL BEAMS 5.12.1 Types of monorail beams Monorail beams used for underslung cranes may be arranged as simple span I-sections or preferably as continuous girders. Curved monorail beams are sometimes dictated by the process. Types of monorail beam splices are shown in Figure 5.12.1.

FIGURE 5.12.1 MONORAIL BEAM SPLICES

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AS 1418.18—2001 5.12.5 Curved monorail beams Where the horizontal radius of the monorail is larger than twice the distance between the girder supports, the designer may neglect to include the effect of curvature and design the girder as if it was straight provided that the monorail extends without joints at least one span on either side of the curved spa n. A curved monorail beam is shown in Figure 5.12.5. In other cases, the curved monorail shall be analysed as a horizontally curved girder.

FIGURE 5.12.5 CURVED MONORAIL BEAM

5.12.6 Marking Monorails shall be marked in a permanent manner with the following information: (a)

Number identifying the beam.

(b)

Rated capacity.

Marking shall be of sufficient size to be legible from the working area below the beam. When the rated capacity of a hoist is not matched to that of the beam, the hoist and the beam shall be marked with the lesser-rated capacity, as appropriate. 5.13 SERVICEABILITY Strict limits on vertical and lateral deflection shall be required to ensure proper service performance of the crane. The following deflection limits at the level of serviceability loads shall apply to runway girde rs and monorails: (a)

Vertical static deflection due to all dead loads and live loads without dynamic factors applied shall not exceed the following:

L 500 (b)

for all runway girders.

Lateral deflection of the top flange induced by inertial forces or off-vertical lifts shall not exceed the following: L or 10 mm, whichever is less. 600 where L = the clear span of the crane runway.

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AS 1418.18—2001 The columns and building frames supporting the runways shall be checked for deflections in order to ensure good tracking behaviour of the cranes. Using the loads at serviceability level, the maximum lateral deflection of the supports at the level of the crane rail shall not exceed— H c or 10 mm, whichever is less 500 where Hc = the height of crane rail above footing The calculated deflections shall take into account the rotation of the footings. Vertical settlement of the footings due to serviceability loads shall not the exceed the lesser of L or 10 mm, whichever is less. 1000 Deflections shall be calculated using dynamic multipliers φ1 = 1 and φ2 = 1. In addition to the deflection limits detailed above, differential rail movement between parallel runways shall be checked to ensure that they do not induce crane wheel flange binding or loading of crane structures.

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AS 1657:2018

Fixed platforms, walkways, stairways and ladders—Design, construction and installation

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AS 1657—2018

90 ° 70 ° 60 °

75°

45°

38 ° 30° 20 °

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10 °

0° * For twin-stile rung-type ladders

FIGURE 2.1 SELECTION OF ACCESS—LIMITS OF SLOPE

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AS 1657—2018

S EC TION

DES IGN

AND

FABR IC AT IO N

3.1 GENERAL DESIGN REQUIREMENTS 3.1.1

General

Where the following materials are used, the design of the structural work comprising the platform, walkways, stairways, ladders, and guardrailing shall conform to the relevant requirements of the listed Standards: (a)

Aluminium ........................................................ AS/NZS 1664.1 and AS/NZS 1664.2.

(b)

Concrete ....................................................................................................... AS 3600.

(c)

Masonry ....................................................................................................... AS 3700.

(d) Timber....................................................................................................... AS

1720.1.

(e) Steel ................................................................... AS/NZS 4600, AS 3990 or AS 4100. (f) Welding ........................................ AS/NZS 1554.1, AS/NZS 1554.6 or AS/NZS 1665. (g) Bolts ...................................................................... AS 1111.1 or AS/NZS 1252 series.

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NOTE: For regulatory purposes, the requirements of the National Construction Code (NCC) take precedence over any conflict with these Standards.

3.1.2 Loading Except where otherwise specified in this Standard, design loadings shall be in accordance with AS/NZS 1170.1. Where loading due to wind or snow is foreseen, provision shall be made for the design loadings of AS/NZS 1170.2 and AS/NZS 1170.3 respectively. Reference shall be made to AS/NZS 1170.0 for appropriate load factors and combinations of actions to determine the design actions (see Notes 3 and 4). NOTES: 1

For wind and snow loadings, the design for serviceability limit states is not required by this Standard.

Imposed actions for particular means of access are specified in the relevant sections of this Standard for that means of access.

Loads given in this Standard are the minimum imposed actions.

Destructive testing for ultimate strength requires the imposed actions specified in this Standard to be multiplied by the appropriate load factor in AS/NZS 1170.0 for design action effect, and again by a further factor for test load from that Standard.

3.1.3 Slip resistance Walking surfaces, including steps, treads and rungs, shall be slip resistant. C3.1.3 It is very important for designers and specifiers to note that the issue of slip resistance should be addressed to ensure the risk of slipping is minimized, and the treatment needs to be in accordance with the likely use of the installation, especially in locations where material build-up, oils and liquids may be present, where users’ shoes may have slip-inducing material on them and where sloping surfaces may exist. Additionally, some grid-style flooring has superior grip in one direction to that at 90°, which also needs to be considered when selecting products. Designers are advised to take account of such issues when selecting flooring materials and to ensure a comparison is made between products before a final decision is made (see also Clause 4.3).

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AS 1657—2018 NOTES: 1

Guidance for the identification and reduction of slip hazards is given in AS/NZS 3661.2 and HB 197.

Suitable test methods of slip resistance for pre-existing and new surfaces are given in AS 4586 and AS 4663.

3.1.4

Difference in height of walkways, platforms and landings

Where the difference in height between adjacent walkways, platforms or landings is greater than 300 mm but does not exceed 450 mm, a minimum of one intermediate step shall be provided. Where the difference in height is 300 mm or less, access from one to the other may be gained without the provision of an intermediate step. Access where the difference in height exceeds 450 mm shall be in accordance with the requirements of Section 7 or by means of a sloping walkway conforming to the requirements of Section 5. 3.1.5

Headroom

The minimum headroom shall be 2000 mm.

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C3.1.5 In applications where helmets are worn, additional headroom may be necessary to accommodate the effective increased height of a person. In limited applications where the minimum headroom cannot be achieved, other measures should be taken to protect the health and safety of users such as padding, highlighting, signage and additional lighting. 3.1.6 Fixing of guardrailing components All guardrailing components shall be securely fixed, to ensure that guardrails, posts and intermediate rails or infill form an integral structure or system. 3.2 MATERIALS 3.2.1

General

Materials shall conform to the requirements of Clauses 3.1.1, 3.2.2 and 3.2.3. 3.2.2 Metals 3.2.2.1

Galvanized steel pipe

Where galvanized pipes are used for their corrosion resistance, they shall be hot-dip galvanized internally and externally in accordance with the requirements of AS/NZS 4680 for hollow sections. 3.2.2.2

Ungalvanized steel pipe

Where ungalvanized steel pipes are used in a corrosive environment, the ends of the pipes shall be sealed to prevent internal corrosion. Corrosion protection in accordance with Clause 3.3.3 shall be applied. 3.2.3

Flooring materials

3.2.3.1

Timber

Timber or plywood floors, treads and toeboards exposed to the weather or high moisture environments shall be of Class 1 or Class 2 durability or be treated in accordance with AS 1604.1 for timber or AS/NZS 1604.3 for plywood. Flooring for platforms, walkways and landings may be of— (a)

dressed or undressed timber; or

(b)

plywood.

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AS 1657—2018 3.2.3.2

Metal plate

Metal plate shall be of chequered, indented or equivalent surface characteristics. The gap between plates shall not exceed 10 mm. NOTE: The gap may be of any length.

3.2.3.3

Concrete

A concrete floor shall be in accordance with AS 3600, wood-float finished or rendered slipresistant. 3.2.3.4

Grating and expanded metal

For grating and expanded metal flooring, the smallest dimension of any opening shall not exceed 45 mm and the area of any opening shall not exceed 5000 mm2. Any gap between adjacent madeup sections of a grated floor shall not exceed 10 mm. NOTE: The gap may be of any length.

Where straightedge bars are not fitted, the size of any opening at the joint between adjacent panels shall not exceed the requirements for openings in the grating, as given in Figure 3.1. NOTE: For trafficable areas below a platform or landing, see Clause 4.5.

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10 max. gap

45 max. opening

10 max. gap

(a) Grating sections with straightedge bars

45 max. opening (b) Grating sections without straightedge bars

DIMENSIONS IN MILLIMETRES

FIGURE 3.1 CLEARANCES BETWEEN ADJOINING PANELS OF GRATING

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AS 1657—2018 3.3 FABRICATION 3.3.1

Welding

Welds shall be dressed smooth, sharp edges removed and, where appropriate, plugs fitted to the end of pipe sections. Welding of steel components shall be in accordance with AS/NZS 1554.1. Welding of stainless steel components shall be in accordance with AS/NZS 1554.6. Welding of aluminium components shall be in accordance with AS/NZS 1665. NOTE: When designing welded aluminium structures, the effect of the heat-affected zone on weld strength should be considered.

3.3.2

Fixings

The methods of attachment shall be capable of sustaining the imposed actions and the environment in which the fixing will be placed (e.g. thermal loading, vibration or chemical attack). NOTES:

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For specific imposed actions for platforms and landings, see Clause 4.2.

For specific imposed actions for walkways, see Clause 5.2.

For specific imposed actions for guardrailing, see Clause 6.1.1.

For specific imposed actions for stairways, see Clause 7.1.1.

For specific imposed actions for fixed ladders, see Clause 7.1.2.

At every attachment level of a ladder, not less than two fixings shall be used (e.g. at the top of the ladder). Any fixing shall have a minimum tensile capacity of 1.5 kN. Fixing shall be designed to prevent floor panels being dislodged and to minimize trip hazards. NOTES: 1

Chemical anchors or expansion-type fixing devices should be installed according to the manufacturer’s instructions.

Deck fixings having heads proud of the walking surface should be avoided but, where used, should be designed to minimize the risk of tripping.

3.3.3 Corrosion protection Equipment and fixings specified under this Standard shall be manufactured from materials that are corrosion resistant or shall be treated to minimize corrosion that can adversely affect their performance. The design of an installation shall minimize the potential for corrosion. NOTES: 1

Various coating systems are detailed in AS 1192, AS 1789, AS 2312.1, AS 2312.2, AS 3566.2 (Class 3), AS/NZS 4680, AS/NZS 4791 and AS/NZS 4792. It is essential to choose the coating that is appropriate for the environment. Powder coatings and anodizing are suitable coating methods for many environments.

The potential for corrosion that can occur when dissimilar metals are brought into contact with one another under certain conditions should be considered.

C3.3.3 Selection of materials or coatings should take the corrosivity of the environment that the equipment and fixings will be exposed to into consideration. AS 4312 describes corrosivity of atmospheric environments and classifies Australian locations according to ISO 9223 corrosivity categories C1 to C5 with increasing corrosivity. Specialist advice should be obtained for materials or coating systems for equipment and fixings used in highly corrosive environments such as sewers, industrial effluent systems, submerged or salt spray environments and chemical plants.

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AS 1657—2018 3.3.4

Floors

All floors shall be evenly laid. Any variation in height between adjacent boards or plates shall not exceed 5 mm.

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NOTE: This does not apply to cleats on sloping walkways (see Clause 5.3.3).

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AS 1657—2018

S EC TION

P LATFOR M S

AND

LAND INGS

4.1 GENERAL REQUIREMENTS 4.1.1 Maximum slope Platforms and landings shall have a maximum slope in any direction of 3°. 4.1.2 Access between adjacent platforms and landings Access between adjacent platforms and landings of different height shall be in accordance with Clause 3.1.4. 4.1.3

Width

The clear width of the walking/working surface of every platform and landing shall be not less than 600 mm. 4.1.4

Headroom

Requirements for headroom above platforms and landings shall be in accordance with Clause 3.1.5.

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4.1.5 Protection Where persons have access to the area below a platform or landing, protection shall be provided in accordance with Clause 4.5. 4.1.6 Design and fabrication The design and fabrication of all platforms and landings shall be in accordance with Section 3. 4.2 DESIGN LOADS FOR FLOORS Floors shall be designed for the dead load of the designed structure plus one of the following minimum imposed loadings, whichever produces the most adverse effects: (a)

A superimposed live loading of not less than 2.5 kPa uniformly distributed.

(b)

A concentrated loading applied through a 100 mm × 100 mm pad of not less than 1.1 kN at any point.

Where the floor of the platform or landing is likely to incur loads exceeding those given in Items (a) or (b) above, reference shall be made to AS/NZS 1170.1 for imposed loads. In all cases, the design actions shall be determined using load factors and combinations of actions according to AS/NZS 1170.0. 4.3 PLATFORM SURFACES Surfaces shall be installed as follows: (a)

All elements and panels shall be securely fixed to the supporting structure and shall not rely on adjacent sections for the prevention of lateral movement. They shall be fixed so that the removal of any element or panel will not affect the security of the remaining sections.

(b)

All elements and panels shall be evenly laid with a maximum variation in height of 5 mm between adjacent sections.

(c)

Where the surface is likely to become wet, provision shall be made to prevent the retention of the liquid by drainage or other means.

(d)

Slip resistance shall be in accordance with Clause 3.1.3.

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AS 1657—2018 (e)

Fixings shall be in accordance with Clause 3.3.2.

(f)

Floors shall be in accordance with Clause 3.3.4.

4.4 GUARDRAILING Guardrailing conforming to the requirements of Section 6 shall be installed on exposed sides of platforms and landings, except for the following: (a)

At the points of access from a stairway or ladder.

(b)

Where there is a permanent structure not more than 100 mm from the edge of the platform or landing capable of providing at least the equivalent protection to guardrailing.

(c)

On the sides and edges of a platform that is not greater than 300 mm above that of an adjacent platform or floor, provided— (i)

the smallest dimension of the upper platform is not less than 1200 mm; and

(ii)

the distance from any edges of the unprotected upper platform to the protection on the edge of the lower platform is not less than 1000 mm.

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Where it is not possible to apply the requirement of Item (c)(ii) above, the minimum height of the protection at the edge of the lower platform shall be increased by 300 mm. The unprotected edges of such platforms shall be marked so that they are clearly visible in their surroundings. NOTE: Figure 4.1 illustrates guardrail details in relation to platform configurations.

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AS 1657—2018 1200 min. Machine or unit to which access is required Raised access or working platform that is not more than 300 above an adjacent platform, walkway or floor

1200 min. 1

Lower platform or walkway on which edge protection in accordance with Section 6 is provided

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Edges of platform to be marked so that they are clearly visible Edge protection in accordance with Section 6

1 PL AN VIEW

Difference in height between levels

Raised platform

Height of guardrail to be as follows. 1 Where width ( W ) is not less than 1000, height ( H ) complies with Section 6. 2 Where width ( W ) is less than 1000, height ( H ) is increased by 300 mm H

D (300 max.)

Width of lower platform or walkway (not less than 600 mm) SECTION

DIMENSIONS IN MILLIMETRES

FIGURE 4.1 GUARDRAILS ON PLATFORMS

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AS 1657—2018 4.5 SAFETY BELOW THE PLATFORM OR LANDING Where persons have access to or work beneath any platform or landing, the floor of such platform or landing shall be designed, or provided with protection, to prevent objects falling through the floor reaching the area below. NOTE: Protection may typically take the form of a lightweight protective barrier fixed beneath the platform, walkway or landing (e.g. 12 mm square mesh).

No aperture in the protection shall permit the passage of a 15 mm diameter ball. 4.6 TOEBOARD Where an object could fall from a platform or landing onto an area to which access by persons is available, a toeboard in accordance with the requirements of Clause 6.1.2 shall be provided. Provided there is a permanent structure within 10 mm of the edge of the platform or landing, this requirement need not apply. 4.7 EDGES

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Where unprotected edges of platforms and landings are not clear because of poor lighting or excessive lighting (e.g. a dark factory, sun on aluminium products, etc.) such that a person may be caused to walk off the edge, the edge shall be clearly identified by highlighting.

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AS 1657—2018

S EC TION

WALKW AYS

5.1 GENERAL REQUIREMENTS 5.1.1 Maximum angle of slope The maximum angle of slope of a walkway shall be as follows: (a)

Level walkway The angle of slope of the walking surface shall not exceed 3° in any direction (see Note 1).

(b)

Sloping walkway The angle of slope of the walking surface in the direction of travel shall not exceed 20° (see Note 2). The angle of slope of the walking surface perpendicular to the direction of travel (i.e. cross-slope) shall not exceed 7° (see Note 3).

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NOTES: 1

A slope of up to 3° may assist with water drainage.

Restricting the slope to between 3° and 10° in direction of travel reduces the risk of slips and trips. See also Figure 2.1.

A slope of between 0° and 3° perpendicular to direction of travel (cross-slope) reduces the risk of slips and trips. However, allowance has been made to enable sloping walkways to be mounted directly onto low-pitched roofs or other surfaces with a resulting walkway crossslope not exceeding 7°.

Where the angle of slope of the walkway exceeds 10° in the direction of travel, cleats conforming to the requirements of Clause 5.3.3 shall be provided. Where the angle of slope exceeds 15°, a method of preventing excessive sliding or rolling in accordance with Clause 5.4.2 shall be provided. 5.1.2 Access between adjacent walkways Access between adjacent walkways of different height shall be in accordance with Clause 3.1.4. 5.1.3

Width

The following requirements apply: (a)

The clear width of a walkway without edge protection shall be not less than 600 mm, as shown in Figure 5.1.

(b)

Where guardrails are installed on both sides of a walkway, the clear width between any elements of the guardrailing shall be not less than 550 mm.

(c)

Where a fixed structure is present on one or both sides of the walkway and is within a 100 mm distance from the walkway, the clear width measured between the structure and the inside surface of any guardrail, or between the two structures, shall be not less than 600 mm. NOTE: If the fixed structure is about 1500 mm above the walkway, the likely contact parts of the structure with a person should be painted with a contrasting colour to highlight the possible contact surface.

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AS 1657—2018 550 mm min.

Between guardrails, intermediate rails or toeboards Guardrail

Intermediate rail (knee rail)

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Toeboard

600 mm min.

Width of walking sur face or length of stair tread

FIGURE 5.1 WALKWAY WIDTH

5.1.4

Headroom

Headroom requirements for walkways shall be in accordance with Clause 3.1.5. 5.1.5

Safety below the walkway

Where persons have access to the area below a walkway, protection shall be provided in accordance with Clauses 4.5 and 4.6. 5.1.6 Design and fabrication The design and fabrication of all walkways shall be in accordance with Section 3. 5.2 DESIGN LOADS FOR WALKWAYS Walkways shall be designed for the dead load of the designed structure plus one of the following minimum imposed loadings, whichever produces the more adverse effect: (a)

A superimposed live loading of not less than 2.5 kPa uniformly distributed.

(b)

A concentrated loading applied through a 100 mm × 100 mm pad of not less than 1.1 kN at any point.

Where the walkway is likely to incur loads exceeding those given in Items (a) or (b) above, reference shall be made to AS/NZS 1170.1 for appropriate imposed loads. In all cases, the design actions shall be determined using appropriate load factors and combinations of actions according to AS/NZS 1170.0.

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AS 1657—2018 5.3 WALKING SURFACES 5.3.1 Installation Walking surfaces shall be installed in accordance with Clause 4.3. 5.3.2 Slip resistance Slip resistance shall be in accordance with Clause 3.1.3. Where the angle of slope of the walking surface is between 10° and 20°, the surface shall have cleats fitted across the full width of the walking surface at 90° to the direction of travel. 5.3.3 Cleats Cleats shall be of metal, not less than 10 mm × 10 mm and evenly spaced at the following intervals: (a)

At slope angles >10° to ≤15° ......................................................................... 450 mm.

(b)

At slope angles >15° to ≤18° ......................................................................... 400 mm.

(c)

At slope angles >18°...................................................................................... 350 mm.

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5.4 GUARDRAILING 5.4.1

Provision of guardrailing

Guardrailing conforming to the requirements of Clause 6.2.1 shall be installed on all sides and ends of a walkway except in the following situations: (a)

At the points of access from a stairway or ladder.

(b)

Where there is a permanent structure not more than 100 mm distant from the edge of the walkway, capable of providing protection at least equivalent to that of guardrailing.

(c)

On the sides and ends of a walking surface that is not more than 300 mm above an adjacent area upon which it is safe to step or stand without risk of falling, and— (i)

the slope of the walkway perpendicular to the direction of travel (cross-slope) does not exceed 3°;

(ii)

the angle of slope of the adjacent area is less than 12°; and

(iii)

the width of the area adjacent to the walkway is greater than 2000 mm (see Note 1).

NOTES: 1

The surface of the adjacent area may not be suitable for walking on regardless of the slope. For such areas, a guardrail or a handrail should be installed to deter persons from stepping onto this area.

Figure 5.2 outlines the typical provisions necessary for the exemption of guardrailing to walkways.

If the angle of slope of the area adjacent to the walkway is 12° or greater, guardrailing conforming to the requirements of Clause 6.2.1 shall be installed on the downslope side of the walkway. 5.4.2

Requirements for walkways with slopes within the range of 15° to 20°

On sloping walkways between 15° and 20°, a handrail conforming to the requirements of Clause 5.6 shall be provided. Where there is a risk of a person sliding or rolling along the sloping surface of the walkway, a means of limiting this linear distance to 18 m shall be installed.

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AS 1657—2018 NOTES: 1

On walkway slopes of lesser angles where there is a risk of a person sliding, a handrail should also be provided.

A means of preventing a person from sliding or rolling a linear distance greater than 18 m may include— (a)

a barrier; or

(b)

a landing not less than 2 m in length; or

(c)

a change in direction of the walkway of nominally 90° with guardrailing fitted at the change in direction to prevent a person moving off the walkway.

2000 min.

300 ma x.

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2000 min.

12 ° ma x.

300 ma x.

b) 2000 min.

12° max.

300 ma x.

c) LEGEND: Walkway Adjacent area DIMENSIONS IN MILLIMETRES

FIGURE 5.2 TYPICAL PROVISIONS OF CLAUSE 5.4.1 WHERE NO GUARDRAIL IS NEEDED

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AS 1657—2018 5.5 TOEBOARD A toeboard conforming to the requirements of Clause 6.1.2 shall be installed on the edge of a walkway where there is no permanent structure within 10 mm of the edge, and from which an object could fall to where persons have access to the area below and to the side of the walkway. Any gap between the underside of the toeboard and the walkway surface shall be not greater than 10 mm. The top of the toeboard shall be not less than 100 mm above the floor. 5.6 HANDRAILS 5.6.1

General

Handrails shall be designed and constructed in accordance with the requirements of this Clause (5.6). Handrails shall have no sharp edges or splinters (which would cause injury to users). Handrails shall meet the imposed action requirement of Clause 6.1.1. Handrails shall not rotate within their fittings. NOTE: Handrails may be supported by ball-type stanchions.

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5.6.2 Height The height of a handrail, measured vertically above the floor, walkway surface or the nosing of a stair tread, shall be not less than 900 mm and not greater than 1100 mm, as shown in Figure 5.3. 5.6.3

Hand clearance

There shall be a hand clearance between the edge of the handrail and any adjacent structure of not less than 50 mm, as shown in Figure 5.4. The handrail shall be supported to permit unrestricted movement of the user’s hand along the upper surface. NOTE: A minimum area of 240 mm should be clear for hand longitudinal movement.

5.6.4

Handrails dimensions

5.6.4.1

Circular

Where circular handrails are provided, they shall be not less than 30 mm and not greater than 65 mm external diameter, as shown in see Figure 5.4(a). 5.6.4.2

Rectangular

Where square or rectangular handrails are provided, they shall be— (a)

not less than 30 mm and not greater than 60 mm width; and

(b)

the sum of height and width shall be within the range 70 mm to 100 mm. NOTE: Refer to Figure 5.4(b).

5.6.4.3

Other shapes

Other shapes may be used for handrails, provided the requirements in accordance with Clauses 5.6.1 to Clause 5.6.3 are met. NOTE: For other shapes of handrails, the dimensions in Clause 5.6.4 may be used as a guide.

5.6.5 Toeboard A toeboard conforming to the requirements of Clause 6.1.2 shall be installed where required by Clause 5.5 and shall be firmly attached to the posts or the floor. Any gap between the toeboard and the floor shall not exceed 10 mm. The top of the toeboard shall be not less than 100 mm above the floor.

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AS 1657—2018

Handrail offset

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900 mm min. 1100 mm ma x.

FIGURE 5.3 HEIGHT RANGE OF HANDRAIL (FIXED TO A WALL) ABOVE WALKING SURFACE

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AS 1657—2018

50 min. clearance

30 min. 65 max.

2 40 ° min area to be clear for and h longitudinal movement

Mounting bracket

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(a) Circular handrails

50 min. clearance

30 ≤ x ≤ 60

70 ≤ x + y ≤ 100

Mounting bracket

(b) Rectangular handrail DIMENSIONS IN MILLIMETRES

FIGURE 5.4 DIMENSIONS OF HANDRAILS

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AS 1657—2018

S EC TION

P HYS IC A L

E DG E

PR OTEC TION

6.1 DESIGN 6.1.1

Guardrailing

Guardrails and intermediate rails (including members and connections that provide structural support) shall be designed to sustain the following imposed actions: (a)

A force of 600 N acting outwards or downwards at any point on the top rail, intermediate rail or post.

(b)

A force of 350 N per linear metre acting outwards or downwards on the top rail or intermediate rail.

(c)

Wind loading in (see Clause 3.1.2).

accordance

with

AS/NZS 1170.2

(external

locations)

The uniformly distributed load, point load and wind loads are not additive and shall be considered as three separate loading situations. All loads shall be positioned on the member for the worst effect.

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No part of the system shall deflect elastically by more than 100 mm under the imposed actions of Items (a) and (b) above. NOTE: The elastic deflection of 100 mm noted above includes the potential deflection of the fixings at the structural support.

6.1.2

Toeboard

A toeboard installed on a platform or walkway shall be designed to withstand a horizontal force of 100 N positioned on the member to achieve the worst effect. The horizontal deflection shall be limited so that the horizontal gap between the inside face of the toeboard and the edge of the walkway or platform does not exceed 10 mm. Under these loads, no part of the system shall elastically deflect by more than 30 mm. NOTE: Additonal requirements for toeboards are given in Clauses 4.6 and 5.5.

6.1.3 Infill Infill that forms part of a guardrail or handrail system, together with members and connections that provide structural support, shall be designed to withstand the greater of following imposed actions: (a)

A horizontal force of 500 N.

(b)

A horizontal pressure of 1 kPa on any infill panel.

(c)

Wind loading in accordance with AS/NZS 1170.2 (external locations), refer to Clause 3.1.2.

The infill shall be tested for strength and rigidity in accordance with Appendix C. 6.1.4

Verification and testing

The stipulated design requirements of this Standard shall be verified by— (a)

detailed engineering calculations of the proposed guardrailing design; or

(b)

testing applied to the proposed guardrailing prototype; or

(c)

both Items (a) and (b) for proprietary systems (i.e. designed for sale to third parties) using the testing specified in Appendices B and C.

Where testing of guardrailing is adopted, it shall be in accordance with the testing procedures of Appendix B and Appendix C, as applicable.

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AS 1657—2018 When tested in accordance with Appendix B, the connections between the guardrail posts and the supporting structure shall withstand the applied test forces of Appendix B. NOTE: The applied test forces are based on the imposed actions given in Clause 6.1.1.

Test reports shall be as specified in Appendix E. NOTE: Guardrailing systems constructed using the recommended materials and dimensions given in Appendix A have been assessed as conforming to the requirements of the requirements of this Standard.

6.2 SPECIFIC REQUIREMENTS 6.2.1

Guardrailing

6.2.1.1

General

Any part of a guardrailing that could come into contact with the user shall have no sharp edges or other attributes that could cause injury to the user. If mobility assistance is required and the guardrail does not provide this, a handrail shall also be provided. Where the guardrail is used as a handrail, it shall meet the requirements of Clause 5.6 and there shall be a minimum hand clearance of 50 mm between the handrail and any adjacent structure.

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The height of a guardrail, measured vertically above the floor, shall be not less than 900 mm. NOTES: 1

For key dimensions of typical guardrailing, see Figure 6.1.

Requirements for handrails are given in Clause 5.6.

C6.2.1.1 Where the fall height from a platform is significant or where persons on the platform may be subjected to wind forces, it is desirable to increase the height of the guardrail to at least 1000 mm to provide a greater sense of security to persons on the exposed platforms. 6.2.1.2

Post and rail construction

Where guardrailing is of post and rail construction, the following requirements apply: (a)

They shall consist of a top rail— (i)

supported by posts at intervals as necessary to meet the specified imposed actions; and

(ii)

parallel to the floor or, where used on a sloping walkway, parallel to the slope of the walkway.

(b)

One or more intermediate rails shall be provided parallel with the top rail and spaced such that the maximum clear space between the rails or between the lowest rail and the toeboard, where fitted, shall not exceed 450 mm.

(c)

Where no toeboard is installed, the clear space between the lowest rail and the floor shall not exceed 560 mm.

(d)

Where removable sections of guardrailing are required, the maximum gap between guardrail elements shall be in accordance with Figure 6.2.

6.2.1.3

Welded mesh construction

Where guardrailing is constructed from welded mesh, the following requirements apply: (a)

The welded mesh shall be supported by posts at intervals to meet the specified imposed actions.

(b)

Such guardrailing shall be provided with a reinforced top edge and be capable of withstanding the imposed actions given in Clause 6.1.1.

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AS 1657—2018 6.2.1.4

Infill

Infill may be constructed from pipe, bar, solid or perforated plate, expanded mesh, weldmesh or other material providing equivalent performance characteristics, taking into consideration strength and sharp edges. The area of any opening shall not exceed 0.2 m2. Expanded metal shall have no sharp edges. Where metal mesh is used, a rigid rail shall be provided as the top rail. Alternatively, the mesh shall be reinforced on the top edge to provide performance equivalent to a top rail. NOTE: Metal mesh includes welded wire, chain or woven construction.

Guardrail

450 ma x.

Intermediate rail 900 min.

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450 ma x. Toeboard 100 min.

10 ma x.

DIMENSIONS IN MILLIMETRES

FIGURE 6.1 TYPICAL GUARDRAILING—KEY DIMENSIONS

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AS 1657—2018

Guardrail Intermediate rail

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25 min. 50 max.

Toeboard omitted for clarity DIMENSIONS IN MILLIMETRES

FIGURE 6.2 MAXIMUM GAP BETWEEN GUARDRAIL ELEMENTS WHERE REMOVABLE SECTIONS ARE REQUIRED

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AS 1657—2018

S EC TION

ACC ES S

BETWEEN

LEVE LS

7.1 DESIGN 7.1.1 Stairways Stairways and integral landings shall be designed for the dead load of the stairway structure plus a superimposed live loading of not less than 2.5 kPa, uniformly distributed on each tread and landing. The maximum deflection shall be L/100 or 40 mm, whichever is the lesser, over the horizontal span (L) of the stairway between supports, including landings where provided. Where the stairs are likely to be loaded in excess of the above requirements, the loading shall be based on the requirements of AS/NZS 1170.1 for imposed actions. Treads shall be designed for a distributed loading of not less than 2.2 kN per linear metre of stair tread width or a concentrated loading of not less than 1.5 kN applied through a 100 mm × 100 mm steel pad, whichever loading produces the more adverse effect. The load shall be applied at the centre of the tread span.

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In all cases, the design actions for stairways shall be determined using load factors and combination of actions according to AS/NZS 1170.0. 7.1.2

Fixed ladders

7.1.2.1

Twin-stile ladders (step-type or rung-type)

Twin-stile ladders and their fixings shall be designed to withstand a concentrated live loading to rungs or treads of not less than 1.5 kN for each 3 m of vertical height within the same ladder flight. The maximum deflection shall be L/100 or 40 mm, whichever is the lesser, calculated with the ladder supported in a horizontal position (span = L) and loaded midspan. Each rung or tread shall be designed to withstand a point load of 1.5 kN at the centre of its span. 7.1.2.2

Single-stile ladders

Single-stile ladders and their fixings shall be designed to withstand a concentrated live loading of not less than 1.5 kN per rung for each 3 m of vertical height within the same ladder flight. The maximum deflection shall be L/100 or 40 mm, whichever is the lesser, calculated with the ladder supported in a horizontal position (span = L) and loaded midspan. Each rung shall be designed to withstand a force of 1.5 kN applied at a point 50 mm from the outside end of the useable rung length. NOTES: 1

Single-stile ladders should be used only where more conventional ladders cannot readily be used.

Typical force application points are shown in Figure 7.1.

7.1.2.3

Individual-rung (step-iron) ladders

A step-iron ladder and its fixings shall be designed to withstand the specified loading and deflection requirements of EN 13101. 7.1.2.4

Design actions for fixed ladders

In all cases, the design actions for twin-stile and single-stile ladders shall be determined using appropriate load factors and combinations of actions according to AS/NZS 1170.0. Individualrung ladders (step-irons) shall conform to the requirements of EN 13101 and Clause 7.6 of this Standard.

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AS 1657—2018 7.1.3 Verification and testing The stipulated design requirements of this Standard shall be verified by— (a)

detailed engineering calculations of the proposed stairway or fixed ladder design; or

(b)

testing applied to the proposed stairway or fixed ladder prototype; or

(c)

both Items (a) and (b) for proprietary systems (i.e. designed for sale to third parties).

Where testing of stairways is adopted, it shall be in accordance with the testing procedure of Appendix D. Where testing of fixed ladders is adopted, the testing procedures shall be based on the loading and deflection requirements given in Clause 7.1.2. NOTE: Appendix F provides guidance on suitable testing procedures that should be used for the testing of fixed ladders.

Test reports shall be as specified in Appendix E.

50 mm

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Rung

Stile

FIGURE 7.1 TYPICAL FORCE APPLICATION POINT FOR SINGLE-STILE LADDER

7.2 STAIRWAYS 7.2.1

Width and angle of slope

Stairways shall be not less than 600 mm wide, measured between the inside edges of the stiles. The clear space between handrails and midrails shall be not less than 550 mm. The angle of slope between the stiles and the horizontal shall be not less than 20° and not greater than 45° (see Figure 2.1). 7.2.2

Flights

The number of risers in a flight shall be not less than two and not more than 18. Where there is more than one flight, adjacent flights shall be connected by a landing conforming to the requirements of Clause 7.2.4. A means of preventing a person from falling more than 36 risers shall be provided, which shall include— (a)

a barrier;

(b)

a landing not less than 2 m in length; or

(c)

a change in direction of the stairway of not less than 90°.

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AS 1657—2018 7.2.3 Stairs 7.2.3.1

Treads

Flooring materials for treads shall be in accordance with the requirements of Clause 3.2.3. The surface of every tread shall extend across the full width of the stairway and the tread surface shall be slip-resistant. 7.2.3.2

Risers and goings

All risers and all goings in the same flight of stairs shall be of uniform dimensions within a tolerance of ±5 mm. NOTE: In some cases, it may be necessary to modify the landing at the base of the stairway to achieve uniformity in the risers.

A riser (R) shall be not less than 130 mm and not greater than 225 mm.

The

going (G) shall be not less than 215 mm and not greater than 355 mm. The going shall be not greater than the tread depth (TD) plus a maximum gap of 30 mm between the rear edge of one tread and the nosing of the tread above. NOTE: For typical terminology of stairway, see Figure 7.2.

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The combination of twice the riser plus the going (2R + G) shall be not less than 540 mm, and not greater than 700 mm [i.e. 540 ≤ (2R + G) ≤700]. 7.2.3.3

Headroom

Headroom requirements for stairways shall be in accordance with Clause 3.1.5. 7.2.3.4

Nosing

The nosing shall be such that the edge of the tread is clearly visible against the background, especially where the stairs could be used in a variety of lighting conditions. 7.2.4

Landings

Any landing at a point of access to the stairway and any intermediate landing in the stairway shall be designed and constructed in accordance with the requirements of Clauses 4.2 and 4.3 and the following: (a)

The length of the landing shall be not less than 600 mm.

(b)

The width of the landing shall be not less than the width of the stairway.

(c)

The landing shall have minimum headroom of 2000 mm.

(d)

Every access landing shall provide standing space of not less than 600 mm clear of crosstraffic, door swing or any other structure.

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AS 1657—2018 Landing Tread

Tread depth ( TD) 185 min. Combination 540 ≤ (2 R + G) ≤ 700 Riser range 130 ≤ R ≤ 225 Landing

Going range 215 ≤ G ≤ 355

Tread gap 30 max.

DIMENSIONS IN MILLIMETRES

FIGURE 7.2 TYPICAL STAIRWAY TERMINOLOGY

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7.2.5

Guardrailing

Except where there is a fixed structure within 100 mm of the stairway stile, stairways and stairway landings shall be provided with guardrailing on any exposed side. Guardrailing shall be in accordance with the requirements of Section 6. The requirement for a toeboard, given in Clause 6.1.2, shall apply only to the sides of stairway landings. 7.2.6 Handrails Every stairway shall be provided with at least one handrail that is continuous between stair flight landings and have no obstruction on or above them that will tend to break a handhold. Where the width of the stairway exceeds 1000 mm, a handrail shall be provided on each side. On adjacent flights of stairs, where the gap between handrails is 100 mm or greater, a continuous rail shall be provided to close the gap for both top and intermediate rails, as shown in Figure 7.3. Where the gap between the handrails is less than 100 mm, a continuous handrail or vertical closure bends shall be used.

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AS 1657—2018 Closure bends side by side

Continuous top and intermediate rails

50 min. 100 ma x.

>100

VIEW A Where gap between handrails is <100

VIEW A Where gap between handrails is >100

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Where the gap between handrails on adjacent stair f l ights is <100 , ver tical closure bends positioned side by side, as shown, may be used at the stair landing. Where the gap is >100 , continuous top and intermediate railing shall be provided

1000 min. preferred Stair landing

Walking sur face Continuous handrailing in accordance with Clause 7. 2. 6 (Some details omitted for clarity) DIMENSIONS IN MILLIMETRES

FIGURE 7.3 CRITERIA FOR HANDRAILS AT LANDINGS

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AS 1657—2018 7.3 STEP-TYPE LADDERS 7.3.1

Width and angle of slope

The width of the step-type ladder between the stiles shall be not less than 450 mm and not greater than 750 mm. The angle of slope of step-type ladders shall be in accordance with the requirements of Section 2. 7.3.2 Ladder enclosures Where a person could fall more than 6 m, the step-type ladder installation shall be fitted with a side screen, or a ladder cage (see Clause 7.4.7), or other type of enclosure to prevent a sideways fall from the ladder.

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NOTES: 1

The side screen should be constructed and mounted to provide a minimum 50 mm and not greater than 90 mm clear space from the ladder handrail to any part of the screen, except where it is fixed to the ladder.

The side screen, measured from its outermost corner should start at a maximum height of 1100 mm above the lower landing and extend to a minimum of 1000 mm above the top landing.

The depth of the side screen, measured perpendicular from the ladder stile, should be a minimum of 750 mm for a ladder slope of 70° to 900 mm for a ladder slope of 60°.

The side screen should contain members or infill such that a 200 mm diameter sphere cannot pass through.

The side screen, together with members and connections that provide structural support, should be designed to sustain the imposed actions for infill given in Clause 6.1.3, acting at any point on the side screen.

Side screens may be fitted to one side only or to both sides of the step-type ladder, as required.

Provision should be made to ensure persons descend a step-type ladder while facing the ladder (e.g. by means of durable warning signs).

7.3.3 Treads 7.3.3.1

Dimensions of treads

Treads shall be not less than 100 mm deep. The surface of every tread shall be slip-resistant. The dimensions of all treads and of all risers in the same step-type ladder shall be uniform and within a tolerance of ±5 mm. 7.3.3.2

Spacing of treads

Treads shall be equally spaced at distances not less than 200 mm and not greater than 300 mm apart. The allowable variation to tread spacing shall be in accordance with Clauses 7.4.3.3 and 7.4.3.4. The spacing of all other treads shall be uniform and within a tolerance of ±5 mm or better. The top tread shall be level with, or be integrated into, the landing. C7.3.3.2 A closer rung spacing tolerance such as ±2 mm, where achievable, will allow for safer movement up and down ladders. The allowable cross-slope at the base of a step-type ladder shall be in accordance with Clause 7.4.3.5.

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AS 1657—2018 7.3.4 Handrails Handrails conforming to the requirements of Clause 5.6 shall be provided on each side of the step-type ladder. The clear space between the handrails shall be not less than 550 mm or greater than 750 mm. The clear distance, measured perpendicular to the slope of the step-type ladder, between the handrails and the plane through the nosing of the treads shall be not less than 150 mm and not greater than 200 mm. NOTE: Typical clearances for handrails are shown in Figure 7.4.

The bottom of the handrails shall commence at a point not more than 900 mm above the landing (see Figure 7.4). NOTE: Where the handrails of a step-type ladder are joined to the handrail of a walkway or platform, either of the following options should be used: (a)

The handrails should be blended to form a smooth transition to allow continuous contact with the handrail while moving from ladder to walkway or platform.

(b)

Alternatively, handrails should be located to— (i)

permit an uninterrupted hand passage along the handrail surface until the user has reached the walkway or platform;

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(ii) ensure a clearance of not less than 50 mm between the handrail surface and any adjacent structure that could contact the user’s hand; (iii) ensure that any gap measured between the ends or components of the handrails does not exceed 100 mm measured horizontally; (iv) follow the slope of the ladder; and (v) avoid the need for direction changes of a magnitude that might affect the user’s stability.

7.3.5 Clearances The minimum clearance between the ladder and all permanent objects that are not part of the ladder installation shall be as follows: (a)

From the nosing of the tread, 200 mm (see Figure 7.4).

(b)

In front, from the nosing of the tread measured perpendicular to the slope of the ladder, 900 mm when the ladder is inclined at 70° to the horizontal, increasing proportionally to 1000 mm when the ladder is inclined at 60° to the horizontal.

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AS 1657—2018

900 min. (1000 pref.)

Toeboard

200 min.

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1000 min. i f 60 ° 900 min. i f 70 °

200 ma x. i f 60 ° 150 min. i f 70 °

Stile Tread

Rise Going

900 ma x.

70 ° ma x. 60 ° min.

DIMENSIONS IN MILLIMETRES

FIGURE 7.4 TYPICAL DIMENSIONS FOR STEP-TYPE LADDERS

7.3.6

Landings

Any landing at a point of access to the ladder and any intermediate landing on the ladder shall be designed and constructed in accordance with the requirements of Clauses 4.2 and 4.3 and the following: (a)

The minimum length of the landing shall be not less than 900 mm, measured horizontally from the face of the lowest rung of the ladder, as shown in Figure 7.5.

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AS 1657—2018 (b)

The width of the landing shall be not less than the width of the ladder or 600 mm, whichever is the greater.

(c)

The landing shall have minimum headroom of 2000 mm.

(d)

Every access landing shall provide standing space of not less than 600 mm clear of crosstraffic, door swing or any other structure.

The vertical distance between landings shall not exceed 6 m. Where the vertical height of the installation exceeds 6 m, and the installation consists of more than one ladder, successive ladders shall— (i)

change direction by 180° at each landing; or

(ii)

be staggered at each landing.

Where ladders are staggered, they shall be spaced with a minimum centre-line to centre-line dimension of 700 mm. Where a change of direction of 180° or staggering is not possible, other means (e.g. a barrier or a landing not less than 1.5 m long) shall be provided to prevent a person falling more than 6 m. NOTES:

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The purpose of the landing is to limit the distance that a person would fall.

The vertical distance between landings in multiple-flight ladders should be equal.

Where installation of intermediate landings is not reasonably practicable (e.g. lighting and transmission towers, wind turbines towers, pits and the like), a fall-arrest system conforming to AS/NZS 1891 series should be provided.

x ≥ 900 mm

FIGURE 7.5 MINIMUM LENGTH OF LANDING

7.4 TWIN-STILE RUNG-TYPE LADDERS 7.4.1 Angle of slope The angle of slope of twin-stile rung-type ladders shall be in accordance with Section 2.

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AS 1657—2018 7.4.2 Stiles 7.4.2.1

Width

The clear width between stiles shall be not less than 375 mm and not greater than 525 mm. 7.4.2.2

Cross-section

The cross-section profile of the stile may be of any shape, provided it fits within a circle not greater than 80 mm and not less than 40 mm diameter. 7.4.3 Rungs 7.4.3.1

General

The surface of rungs shall be slip resistant (e.g. corrugated, serrated, knurled, dimpled or coated with a slip-resistant material). Rungs shall be securely connected to the stiles and shall not rotate. Rungs shall be not less than 20 mm diameter and not greater than 50 mm diameter. Where the ladder is of steel construction, the completed ladder shall be either hot-dip galvanized or treated with an effective corrosion-preventive material appropriate to the location (see Note 3).

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NOTES: 1

Cross-sections other than circular may be used.

The size and shape of the rung surface will also affect the comfort and therefore the safety of persons using the ladders for extended periods. The maximum practicable rung surface area is desirable, taking into account the ability to grip the rung by hand.

The corrosion-preventive treatment should not adversely affect the slip resistance of the working surfaces.

C7.4.3.1 The 20 mm diameter requirement is to ensure adequate handgrip. As is now common in temporary aluminium ladders, the rungs may be shaped with a flatter top to assist with more comfortable and safer loading of user’s footwear. 7.4.3.2

Spacing of rungs

Rungs shall be spaced as follows: (a)

For ladders having a length greater than 1 m, a rung spacing of not less than 250 mm and not greater than 300 mm.

(b)

For ladders having a length less than or equal to 1 m, rungs shall be evenly spaced but not greater than 300 mm apart.

The allowable variation to rung spacing shall be in accordance with Clauses 7.4.3.3 and 7.4.3.4. The spacing of all other rungs and the dimensions of all rungs in the same ladder shall be uniform and within a tolerance of ±5 mm or better. C7.4.3.2 A closer rung spacing tolerance such as ±2 mm, where achievable, will allow for safer movement up and down ladders. 7.4.3.3

Variation of top rung/tread spacing

The top rung/tread shall be at the same height as the top landing, as shown in Figure 7.6.

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AS 1657—2018

Top rung at the same height as landing

x x x x

NOTE: Measured ver tically.

Top tread at the same height as landing for rung ladders

150 mm min.

x x

0.9 x min. 0. 9 x min.

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7° Cross- slope base 7° max Max. allowable dimensional variations rung- type ladder

FIGURE 7.6

7.4.3.4

Up to 7° cross- slope across base step-type ladder

VARIATION OF RUNG/TREAD SPACING

Variation of bottom rung/tread spacing

The distance between the bottom rung/tread and the bottom landing shall be not less than 90% and not greater than 100% of the rung/tread spacing (see Figure 7.6). NOTES: 1

This distance should be measured at the ladder centre-line where the landing has a cross-slope (see Figure 7.6).

Where possible, the distance between the landing and the first rung/tread should be equal to rung/tread spacing.

the

C7.4.3.4 The allowable variations given in this Clause and the rung/tread spacing tolerances referred to elsewhere in this Standard are not equivalent; the tolerance is a manufacturing allowance and is not intended to be cumulative. The allowable variation is a dimension that may be varied intentionally by the design. 7.4.3.5

Allowable cross-slope at base of ladder

A bottom landing cross-slope of up to 7° total is permissible, to cater for a typical low slope surface for the bottom landing (e.g. a roof) without the need for a horizontal platform. NOTE: The allowable cross-slope is shown in Figure 7.6. The preferred position is for the bottom landing at the ladder base to be horizontal, where possible. In some cases, it may be necessary to provide a separate bottom landing platform and, in such cases, additional attention may need to be given to potential trip hazards, visibility of edges and the like.

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AS 1657—2018 7.4.4 Fastenings The ladder shall be secured with fastenings at the top and at the foot of the ladder, and secured at intervals as necessary for conformance with the requirements of Clause 7.1.2. The loads on the ladder and the maximum deflection limits (see Clause 7.1.2) shall determine the type and distance between the fastenings. NOTE: The ladder should be also secured at intervals that are sufficient to minimize lateral swaying.

7.4.5 Clearances

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As a minimum, clearances between the ladder and all permanent objects that are not part of the ladder installation shall be the following: (a)

At the back edge of the rung, 200 mm.

(b)

In front, from the nosing of the rung measured at perpendicular to the ladder, 750 mm.

(c)

At the sides, 350 mm from the centre-line of the ladder, except as provided in Item (d) below.

(d)

From a line drawn from the stile at an angle of not less than 135° to the front of the rung.

The hand clearance for stiles shall be not less than 50 mm. Where a ladder is provided with a cage, the minimum clearance dimensions specified in Items (b) and (c) above shall be modified in accordance with the requirements of Clause 7.4.7. NOTE: Typical minimum clearances are shown in Figure 7.7.

7.4.6

Landings

Landings for twin-stile ladders shall be in accordance with the requirements of Clause 7.3.6. 50

200

135° 750

350

DIMENSIONS IN MILLIMETRES

FIGURE 7.7 TYPICAL MINIMUM CLEARANCES FOR RUNG-TYPE LADDERS

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AS 1657—2018 7.4.7 Ladder cage A ladder cage conforming to this Clause shall be provided where a person could fall more than 6 m from a rung-type ladder, irrespective of landings. Where installation of a ladder cage is not possible (e.g. lighting and transmission towers, wind turbines towers, pits and the like), a fall-arrest system conforming to AS/NZS 1891 series shall be provided. NOTES: 1

The determination of a potential fall from the ladder should take account of not only a vertical fall but, additionally, the potential for a continuing fall past a lower landing.

Consideration should be given to installing a ladder cage for fall heights of less than 6 m, irrespective of landings.

See Figures 7.8 and 7.9 for ladder cage details and dimensions.

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Where a ladder cage is provided, it shall conform to the following: (a)

The inside of the cage shall be free from projections.

(b)

The ladder cage shall be constructed so that any opening does not permit a 150 mm sphere to pass through it.

(c)

The cage shall extend not less than 1000 mm or to the height of the guardrail (if provided) above the top of the platform landing.

(d)

The bottom of the cage shall terminate not less than 2000 mm and not greater than 2200 mm above the base of the ladder. NOTE: The bottom portion of the cage may be flared out and may extend to any adjacent guardrails.

(e)

Where the bottom of the ladder terminates at a platform fitted with guardrailing that is less than 900 mm horizontally from the front of the ladder, the area between the cage and the top of the guardrailing shall be fitted with edge protection.

(f)

Where the bottom of the ladder terminates at a platform fitted with guardrailing that is less than 500 mm laterally from the outside of either ladder stile, the area between the cage and the top of the guardrailing shall be fitted with edge protection.

(g)

The rear half of the cage shall be approximately semicircular. The sectional dimensions of the cage shall provide an internal width of 700 mm and a clearance of 750 mm between the back of the cage and the front of the rungs, measured at 90° to the slope of the ladder.

(h)

Cage hoops shall be constructed of minimum 50 mm × 5 mm low carbon steel flat or an equivalent component having comparable performance, spaced at not more than 2000 mm centres. As a minimum, cage verticals shall be— (i)

25 mm × 5 mm low carbon steel or an equivalent component having comparable performance, spaced in accordance with Item (b) above;

(ii)

welded wire mesh not less than 3 mm thick, with openings not exceeding 100 mm × 100 mm; or

(iii)

chain wire mesh, supported by not less than seven vertical bars around the circumference of the cage.

NOTE: In the context of ‘comparable performance’ in relation to bending strength, rigidity and safety, a cage hoop constructed from a thin section could introduce a cutting or severing hazard.

(i)

Connections shall be either welded or mechanically fastened.

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AS 1657—2018

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C7.4.7 For ladders erected in highly scenic or other locations that are accessible to the public, consideration should be given to preventing unauthorized access. Suitable methods may include fitting a lockable gate to the entry to the ladder cage, guarding to the back of the ladder for the first 3 m from the lower end of the cage and making the ladder cage difficult to climb on the outside by covering the first 3 m with robust mesh having openings too small for toe holds.

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AS 1657—2018 375 - 525

375 - 525

45°

750

350

Option ‘B’

Option ‘A’

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(a) Options

Ladder stile (typ.)

Flat bar welded to side of stile. Position relative to rung not critical

(b) Ladder suppor t bracket installation

Ladder cage hoop welded to side of stile. Position relative to rung not critical

FIGURE 7.8 CLEARANCES AND MOUNTING DETAILS FOR LADDER CAGES

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AS 1657—2018

For details of cage hoops and ver ticals see Clause 7. 4.7

1000 min.

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2000 ma x. spacing

2200 ma x. 2000 min.

DIMENSIONS IN MILLIMETRES

FIGURE 7.9 TYPICAL LADDER CAGE DIMENSIONS

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AS 1657—2018 7.4.8

Extension above landings

7.4.8.1

Step-through ladders

Where it is necessary for a person to step through a ladder, the stiles shall extend not less than 1000 mm above the top landing. The width between the extended stiles at the top shall be not less than 525 mm and not greater than 675 mm. NOTE: For typical stiles for step-through ladder, see Figure 7.10.

Stile strength and load capacity shall be consistent with the ladder. The maximum deflection of the extended stiles shall be limited to Ls/50, where Ls is the length of the extended stile and the imposed action is a force of 600 N acting outwards at 90° to the slope of the ladder and positioned at the top of the extended stile. The maximum lateral deflection of the extended stiles shall be limited to Ls/15, where Ls is the length of the extended stile and the imposed action is a force of 350 N acting laterally in the plane of the ladder and positioned at the top of the extended stile. Except at points where a ladder cage and other brackets are attached, hand clearances around the stiles shall be maintained at 50 mm.

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NOTE: For stile clearance, see Clause 7.4.5.

525 mm to 675 mm

FRONT VIEW

1000 mm

min.

SIDE VIEW

FIGURE 7.10 TYPICAL STILES FOR STEP-THROUGH LADDERS

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AS 1657—2018 7.4.8.2

Side access ladders

Where it is necessary for a person to step sideways from a ladder, the ladder stiles and rungs shall extend not less than 1000 mm above the top landing. The horizontal distance from the ladder stile to the landing shall be 90 mm to 175 mm. NOTES: 1

For typical stiles and rungs for side access ladders, see Figure 7.11.

Figure 7.11 shows a typical arrangement for side access from a ladder to a landing. The design of such installations should consider the adequacy of the space between the ladder stile and adjacent edge protection railing to allow safe access, and also the size of the gap between the ladder stile and the adjacent landing, where an infill section or extension to the landing may be appropriate.

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Guardrailing

90 mm to 175 mm

Rung level with landing FRONT VIEW

SIDE VIEW

FIGURE 7.11 TYPICAL SIDE ACCESS LADDERS

7.4.8.3

Access through horizontal openings

Where access is provided through a horizontal opening (e.g. through a roof access hatch)— (a)

the stiles or handrails shall extend not less than 1000 mm above the opening; or

(b)

handgrips above the level of the opening shall be provided.

NOTE: Where access is provided through an opening that is normally kept closed, the stiles or handrails may be terminated below the opening and handgrips mounted above.

Where it is necessary for a person to open a trapdoor while standing on a ladder, provision shall be made for opening and closing the roof access hatch by remote means, or by the use of one hand. Where it is necessary for a person to extend the stiles or handrails while standing on a ladder— (i)

provision shall be made for performing this task by remote means, or by the use of one hand; or

(ii)

a platform shall be provided to enable the opening of the trapdoor and extension of stiles.

the

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AS 1657—2018 7.4.8.4

Ladder landing

The angle of the slope of the top landing shall not exceed 3° in any direction (see Note 1). The foot of the ladder shall rest on, or terminate above, the landing (see Note 2). Where the ladder provides access to a landing, the landing shall be at the same height as the top rung. The landing shall extend to the top rung, or there shall be a gap of not less than 50 mm and not greater than 100 mm between the top rung and the landing (see Note 3). Ladder landings shall extend forward to at least the projected line of the rear of the stile (see Note 4). NOTES: 1

For the cross-slope of bottom landings, see Clause 7.4.3.5.

For the required dimensions of landings, see Clause 7.3.6.

For landings level with the top rung, see Figure 7.12(a).

For bottom landings extending forward, see Figure 7.12(b).

7.4.8.5

Handrails

Handrails mounted on stile extensions and projecting towards the user shall not be used (see Note 1).

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Handrails mounted on stile extensions and projecting away from the user may be used as an aid to access. NOTES: 1

This requirement is to discourage users from moving their centre of gravity further away from the rungs by gripping the handrails.

Guidance on handrails projecting from stile extensions is given in Appendix I.

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AS 1657—2018 No gap or 50 to 100 Hand clearance to stile 50 min. 5 0 max.

Rung spacing

200 min.

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(a) Top rung level with landing 900

Rung spacing

200 min.

Landing

Min. projection of rear of stile (b) Base detail DIMENSIONS IN MILLIMETRES

FIGURE 7.12 TYPICAL GAP BETWEEN LANDING AND LADDER

7.5 SINGLE-STILE RUNG-TYPE LADDERS 7.5.1

General

This Clause (7.5) sets out requirements for single-stile rung-type ladders. Single-stile rung-type ladders are typically installed where other means of access cannot be used. Where single-stile rung-type ladders exceed 3.5 m in fall distance, a fall-arrest system conforming to AS/NZS 1891 series shall be provided. 7.5.2 Angle of slope The angle of slope shall be not less than 85° to the horizontal. In no case shall the ladder overhang the person climbing the ladder.

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AS 1657—2018 7.5.3 Stile cross-section The front face of central stiles shall not exceed 80 mm in width. NOTE: See Figure 7.13 for a typical central stile cross-section.

Other cross-sections conforming to the design requirements of this Standard may be used, taking into account that stile is generally used to support rungs and act as the runner for a harness-based fall-arrest system and, as such, needs to be rated for fall-arrest fall loads. 7.5.4 Rungs 7.5.4.1

General

Rungs for single-stile ladders shall be in accordance with the requirements of Clause 7.1.2.2. The following requirements also apply: (a)

Rungs shall be not less than 20 mm outside diameter. NOTES:

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1 2

Cross-sections other than circular are permitted and slip-resistant surfaces are recommended. Rungs should provide a comfortable surface upon which to stand.

(b)

Rungs shall be securely fastened to the stile (e.g. by welding or swaging). In highly corrosive areas, rungs shall be completely sealed at the point where they enter or make contact with the stiles.

(c)

The point of attachment of the rung to the stile shall be smooth and free from projections likely to cause injury to the hands or legs.

(d)

Rungs shall be of the same level on both sides of the stile and shall be upturned at the ends for a minimum of 25 mm, as shown in Figure 7.13. The clear width between the upturned ends of the rungs shall be not less than 375 mm and not greater than 550 mm.

7.5.4.2

Rung spacing

Rungs shall be spaced as follows: (a)

For ladders having a length greater than 1.5 m, not less than 250 mm and not greater than 300 mm.

(b)

For ladders having a length equal to or less than 1.5 m, not less than 200 mm and not greater than 300 mm.

The allowable variation to rung spacing shall be in accordance with Clauses 7.4.3.3 and 7.4.3.4. The spacing of all other rungs shall be uniform and within a tolerance of ±5 mm. The top rung shall be at the same height as, or integrated into the landing. The allowable cross-slope at the base of the ladder shall be in accordance with Clause 7.4.3.5. C7.5.4.2 A closer rung spacing tolerance such as ±2 mm, where achievable, will allow for safer movement up and down ladders.

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AS 1657—2018

200 min.

80 ma x.

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Top rungs to be level with landing

150 min. 250 ma x.

Landing

25 min.

200 min. to 300 ma x. for ladder having a ver tical height less than 1500 250 min. to 300 ma x. for ladder having a ver tical height of 1500 or greater

Ver tical distance between landings 6000 ma x.

Ø20 min.

Landing

DIMENSIONS IN MILLIMETRES

FIGURE 7.13 PRINCIPAL DIMENSIONS OF SINGLE-STILE RUNG-TYPE LADDERS

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AS 1657—2018 7.5.4.3

Fastenings

The ladder shall be secured with fastenings at the top and at the foot of the ladder and at intervals, to minimize lateral swaying and twisting during use. The design of the ladder shall determine the distance between the fastenings and shall take account of potential twisting of the ladder as a person climbs or descends the ladder. NOTE: The fastenings should be on the back of the ladder.

7.5.5 Clearances Clearances between the single-stile ladder and all permanent objects that are not part of the ladder installation shall be in accordance with the requirements of Clause 7.4.5. 7.5.6

Landings

Landings for single-stile ladders shall be in accordance with the requirements of Clause 7.3.6. 7.5.7

Extension above landings

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7.5.7.1

General

Where it is necessary for a person to step off the ladder onto a landing, the ladder shall extend not less than 1500 mm above the landing level and provision shall be made to ensure that any fall-arrest system remains connected while the user moves onto the landing and, if necessary, connects to another anchor point before disconnection from the ladder fall-arrest system. 7.5.7.2

Side access

A ladder rung shall be located level with the landing and any fall-arrest system shall be configured to allow the user to move to the landing and, where required, transfer safely to another anchor system before disconnection from the fall-arrest system on the ladder. The horizontal distance from the centre-line of the ladder to the landing edge shall be 400 mm to 450 mm. 7.5.7.3

Access through horizontal openings

Where access is provided through a horizontal opening (e.g. through a trapdoor or roof hatch), the following requirements shall apply: (a)

The ladder shall extend not less than 1500 mm above the opening.

(b)

Handgrips above the level of the opening shall be provided. Provision shall be made for the user to safely connect to an alternative anchor system before disconnection from any fall protection system on the ladder.

Where it is necessary for a person to open a trapdoor while standing on a ladder— (i)

provision shall be made for opening the trapdoor by remote means, or by the use of one hand; or

(ii)

a platform shall be provided to enable the opening of the trapdoor.

7.5.8 Ladder stile The foot of the ladder stile shall terminate at or within 150 mm of landing, and the rear face of the first rung shall be within the vertically projected area of the landing. NOTES: 1

For the required dimension of landings, see Clause 7.3.6.

Where guardrails are fitted to the landing platform, toeboards should not extend across ladder openings.

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AS 1657—2018 7.5.9 Handrails Handrails shall not be used on single-stile rung-type ladders. 7.6 INDIVIDUAL-RUNG (STEP-IRON) LADDERS 7.6.1

General

Step-iron ladders shall be in accordance with this Clause (7.6) and with the general requirements and test methods of EN 13101, which applies to step-irons manufactured from cast iron, steel or aluminium. Where a conflict occurs, the requirements of this Clause (7.6) shall prevail. NOTES: 1

EN 13101 specifies performance criteria for mechanical stability and resistance of step-irons. Corresponding test methods and evaluation conformity are included.

A step-iron type ladder should only be used where it is not reasonably practicable to use any other type of ladder.

7.6.2 Angle of slope The angle of slope shall be not less than 80° to the horizontal (see Figure 2.1). In no case shall the ladder overhang the person climbing the ladder.

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7.6.3

Rungs

7.6.3.1

General

The rungs for step-iron ladders shall conform to the following requirements: (a)

The rungs shall be of size and cross-sectional shape conforming to the performance criteria of EN 13101 and this Standard.

(b)

The rungs shall be manufactured from cast iron, steel, aluminium or other material in accordance with EN 13101.

(c)

The rungs shall be provided with corrosion protection (e.g. plastic encapsulation) in accordance with EN 13101. NOTES: 1

Corrosion protection measures include hot-dip galvanizing, electroplated galvanizing, anodizing or plastic encapsulation.

Corrosion protection should ensure the durability of the rungs for the design life of the structure in which they are embedded.

Where step-irons are to be used in highly corrosive environments, additional corrosion protection measures may be required. For example, electroplated galvanizing may be used together with plastic encapsulation.

Highly corrosive environments include sewers, industrial effluent systems, marine or salt spray environments and chemical plants.

Alternative design methods and materials may be used, provided it can be demonstrated result satisfies the requirements of this Clause (7.6).

Figures 7.13 to 7.16 provide typical details and dimensional notation for step-iron type ladders.

7.6.3.2

the

Rung spacing

Rungs shall be spaced as follows: (a)

For ladders having a length of greater than 1 m, a rung spacing of not less than 250 mm and not greater than 300 mm.

(b)

For ladders having a length of less than or equal to 1 m, rungs shall be evenly spaced but not greater than 300 mm apart.

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AS 1657—2018 The distance between rungs, including landing to the bottom rung, in the same ladder shall be uniform and within a tolerance of ±5 mm. 7.6.3.3

Rung dimensions

The minimum diameter of the rung or width of the tread (T) shall be 20 mm. NOTE: For typical examples, see Figures 7.14 and 7.15.

The minimum length of the tread (L) shall be 150 mm for single steps and 350 mm for double steps. The maximum length of the tread (L) shall be 550 mm. The minimum clearance to the back edge of the rung (P − T) shall be— (a)

100 mm where the ladder access effective diameter is less than 650 mm; and

(b)

150 mm where the ladder access effective diameter is 650 mm and over.

The rungs shall be provided with a minimum upstand height (H) of 20 mm on each end of the tread so that the foot cannot slip off the end of the rung. All other dimensional requirements for the rungs shall be in accordance with EN 13101. The dimensions of all rungs on the same ladder shall be uniform and within a tolerance of ±2 mm.

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The rungs shall be in accordance with the load testing and deflection requirements of EN 13101. 7.6.3.4

Fastenings

Every rung shall be permanently fixed to the adjoining structure or equipment. Rungs shall be fixed so as to be coplanar where possible. The use of cranked rungs on circular or curved walls is permitted. NOTE: For an example of coplanar rungs, see Figure 7.17.

7.6.3.5

Product testing and evaluation

The rungs for step-iron ladders shall conform to the initial type testing and factory production control requirements of EN 13101, with the following modifications: (a)

The size of a production lot for factory production control shall be ≤5000 specimens.

(b)

There shall be no limit on the maximum number of production days.

NOTE: For further details of the product testing and evaluation requirements, see EN 13101.

7.6.4

Landings

Landings for step-iron ladders shall be in accordance with the requirements of Clause 7.3.6. NOTE: The vertical rise for a step-iron ladder should not exceed 6 m. Where this is not reasonably practicable, one or more landings should be used and the vertical distance between landings should not exceed 6 m.

7.6.5 Ladder cage A ladder cage conforming to Clause 7.4.7 shall be provided where— (a)

the ladder access minimum clearance in front of the rungs is greater than 750 mm; and

(b)

a person could fall more than 6 m from a step-iron ladder, irrespective of landings.

Where installation of a ladder cage is not possible (e.g. lighting and transmission towers, wind turbines towers, pits and the like) a fall-arrest system conforming to AS/NZS 1891 series shall be provided.

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AS 1657—2018

S EC TION 8 LABE LLING DOC UM ENTAT ION

A N D

8.1 GENERAL This Section sets requirements for labelling and documentation that shall be provided for the platform, walkway, stairway, guardrailing or ladder (the system). 8.2 LABELLING OF INSTALLATION

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The system installation shall bear a permanent label, in a readily visible position, that indicates— (a)

the name of the manufacturer of the platform, walkway, stairway, guardrail or ladder;

(b)

the name of its installer;

(c)

the name of the certifier of the system (if any);

(d)

the date of installation;

(e)

a statement of the system’s conformance to this Standard and its installation in accordance with its manufacturer’s instructions; and

(f)

where regular inspection/testing of the installation is required, the date of inspection or the current ‘until’ date.

The label shall be of a size that is clearly legible for the expected life of the installation, and shall be durable and suitable for the environment in which it is to be located, with an expected minimum life of 7 years. Where any area of the installation does not conform to the requirements of this Standard, a statement detailing the area of non-conformance shall be included on the installation certificate, and an additional label, stating the non-conformance, shall be affixed to the installation. 8.3 DOCUMENTATION TO BE SUPPLIED The following documentation shall be supplied for each system installation: (a)

Conformance statement setting out level of conformance to this and other relevant Standards.

(b)

Listing of any unique component serial numbers.

(c)

Listing of any special provisions for use (e.g. training, additional equipment, higher than normal levels of supervision, rescue provisions, etc.).

(d)

The required frequency of inspection, testing and servicing for all equipment.

(e)

Additional information as relevant (e.g. load ratings where limitations apply, provisions for fall-arrest attachments and loadings).

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AS 1657—2018

APPENDIX A

RECOMMENDED COMPONENT DIMENSIONS AND MATERIALS FOR EDGE PROTECTION (Informative) This Appendix provides information on minimum component dimensions and materials (Tables A1, A2 and A3) that should be used where edge protection components have not been specifically designed and tested in accordance with Clause 6.1. TABLE A1 RECOMMENDED MINIMUM DIMENSIONS FOR TYPICAL STEEL COMPONENTS Steel dimensions and shape

Steel pipe (outside diameter)

Posts

65 × 65 × 5 angle

48.3 × 3.2 wt

Top rail

50 × 50 × 5 angle

33.7 × 3.2 wt

Intermediate rails (parallel to guardrail/handrail or vertical)

40 × 40 × 5 angle

26.9 × 3.2 wt

100 × 6 flat

—

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Component

Toeboards LEGEND: wt = wall thickness

NOTE: Based on 1000 mm post height and 2400 mm post spacing.

TABLE A2 RECOMMENDED MINIMUM DIMENSIONS AND PROPERTIES FOR TYPICAL ALUMINIUM COMPONENTS—MECHANICAL FIXINGS ONLY (NOT TO BE USED FOR WELDED FABRICATIONS) Component Posts

Aluminium shape and dimensions

Alloy and temper range

65 × 65 × 2.5 square hollow 60 × 5 round tube 60 × 50 × 3 rectangular hollow

Class 1 or Class 2 alloys

50 × 50 × 2 square hollow 50 × 3 round tube

Class 2 alloys

Guardrail/handrail

50 × 50 × 1.6 square hollow 50 × 3 round tube

Class 1 or Class 2 alloys

Intermediate rail

38 × 2 round tube

Class 1 or Class 2 alloys

Toeboard (fixed at midspan)

100 × 6 flat bar

Class 1 or Class 2 alloys

NOTE: Based on 1000 mm post height and 2000 mm post spacing.

TABLE A3 ALUMINIUM ALLOY CLASSES RELEVANT TO TABLE A2 Class

Alloys

6060-T5, 6063-T5, 6063-T6

6061-T6, 6005A-T5, 6005A-T61, 6351-5, 6351-T6, 6082-T5, 6082-T6

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AS 1657—2018

APPENDIX B

TESTING OF GUARDRAILING COMPRISING RAILS AND POSTS (Normative) B1 INTRODUCTION This Appendix sets out a method for assessing the strength and rigidity of the following components: (a)

Top rails comprising guardrails or handrails.

(b)

Intermediate rails.

(c)

Posts.

(d)

Fixings of the railing system.

NOTE: Where an intermediate rail is of the same material and dimensions as a top rail it does not require separate testing.

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B2 PRINCIPLE A section of the railing system, consisting of two posts, rails (etc.) is mounted on a rigid base using the mounting method intended for the installation (see Figure B1). Non-simultaneous horizontal and vertical forces are applied to the post and top rails and any resulting deflections are measured. NOTE: Additional tests (not detailed in the Standard) may be required to determine the performance of the connection between the railing system and the supporting medium, e.g. roof sheeting.

B3 APPARATUS The following apparatus is required: (a)

A rigid foundation to which the railing system can be attached. The rigid foundation shall be a representative structure of the intended fixing foundation for actual service.

(b)

A means of applying a horizontal point load to the post.

(c)

A means of applying a horizontal and vertical point load to the top rail.

(d)

A means of applying a horizontal or vertical uniformly distributed load (UDL) to the top rail.

(e)

A means of timing an interval of 60 s (e.g. a stopwatch).

(f)

A means of measuring deflection of the post or rail to within 1 mm.

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AS 1657—2018 FORCE ( tests 1 and 5 )

Deflection-measuring means

(a) Single post

FORCE ( test 3)

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FORCE (test 2)

= =

Deflection-measuring means

(a) End post on rail panels

FIGURE B1 GUARDRAIL AND POST TEST ASSEMBLY SHOWING POSSIBLE TEST LOCATIONS

B4 PROCEDURE NOTE: See also Figure B1.

B4.1 Assembly The railing system shall be securely fixed to the rigid foundation. NOTE: This should be fixed in the manner intended by the designer.

The framework to support the deflection-measuring devices shall be rigidly fixed and independent of the test sample. B4.2 Test forces The test forces shall be based on the imposed actions as given in Clause 6.1.1. B4.3 Deflection Displacement readings shall be taken on the test sample at nominated framing member locations that represent actual structural movement. As a minimum, these shall be at the top of posts and midspan of the top rail.

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AS 1657—2018 B4.4 Preload An initial force equivalent to 50% of either the imposed action point load or the imposed action UDL shall be applied to the test sample for 1 min. This shall be taken as the settling-in or taking-up period. B4.5 Test 1: Horizontal point load at top of post—Deflection The procedure shall be as follows: (a)

Preload the test sample as specified in Paragraph B4.4.

(b)

Remove the preload force and set the deflection-measuring device to zero.

(c)

Gradually increase the force acting on the top of the post until the imposed action specified in Clause 6.1.1 is reached. Hold the test force for 1 min.

(d)

Record the deflection at the top of the post.

(e)

Remove the test force and after 2 min record the permanent deflection reading.

B4.6 Test 2: Horizontal point load on top rail or intermediate rail—Deflection The

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procedure shall be as follows: (a)

Preload the test sample as specified in Paragraph B4.4.

(b)

Remove the preload force and set the deflection-measuring device to zero.

(c)

Gradually increase the force acting on the midspan of the rail until the imposed action specified in Clause 6.1.1 is reached. Hold the test force for 1 min.

(d)

Record the deflection at the midspan of the guardrail.

(e)

Remove the test force and after 2 min record the permanent deflection reading.

B4.7 Test 3: Vertical point load on top rail or intermediate rail—Deflection The procedure shall be as follows: (a)

Preload the test sample as specified in Paragraph B4.4.

(b)

Remove the preload force and set the deflection-measuring device to zero.

(c)

Gradually increase the force acting on the midspan of the rail until the imposed action specified in Clause 6.1.1 is reached. Hold the test force for 1 min.

(d)

Record the deflection at the midspan of the guardrail.

(e)

Remove the test force and after 2 min record the permanent deflection reading.

B4.8 Test 4: Horizontal UDL on top rail or intermediate rail—Deflection The procedure shall be as follows: (a)

Preload the test sample as specified in Paragraph B4.4.

(b)

Remove the preload force and set the deflection-measuring device to zero.

(c)

Gradually increase the force acting on the side of the rail until the imposed action specified in Clause 6.1.1 is reached. Hold the test force for 1 min.

(d)

Record the deflection at the top of the post and at the midspan of the guardrail.

(e)

Remove the test force and after 2 min record the permanent deflection reading.

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AS 1657—2018 B4.9 Test 5: Horizontal point load at top of post—Ultimate The procedure shall be as follows: (a)

Preload the test sample as specified in Paragraph B4.4.

(b)

Remove the preload force and set the deflection-measuring device to zero.

(c)

Gradually increase the force acting on the top of the post until the ultimate test force equal to 2 × the imposed action specified in Clause 6.1.1 is reached. Hold the test force for 1 min.

(d)

Remove the test force and after 2 min record the permanent deflection reading.

B4.10 Test 6: Horizontal UDL on top rail or intermediate rail—Ultimate

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The procedure shall be as follows: (a)

Preload the test sample as specified in Paragraph B4.4.

(b)

Remove the preload force and set the deflection-measuring device to zero.

(c)

Gradually increase the force acting on the side of the rail until the ultimate test force equal to 2 × the imposed action specified in Clause 6.1.1 is reached. Hold the test force for 1 min.

(d)

Remove the test force and after 2 min record the permanent deflection reading.

B4.11 Test 7: Horizontal point load on top rail or intermediate rail—Ultimate The procedure shall be as follows: (a)

Preload the test sample as specified in Paragraph B4.4.

(b)

Remove the preload force and set the deflection-measuring device to zero.

(c)

Gradually increase the force acting on the side of the rail until the ultimate test force equal to 2 × the imposed action specified in Clause 6.1.1 is reached. Hold the test force for 1 min.

(d)

Remove the test force and after 2 min record the permanent deflection reading.

B5 PASS/FAIL CRITERIA B5.1 Tests 1 to 4 The deflection at the top of the post shall not exceed 100 mm under load and the post shall return to within 20 mm of its original position upon removal of the test loads. The deflection of the top rail or intermediate rail shall not exceed 100 mm under load in relation to the deflected position of the supporting posts. The rail shall return to within 20 mm of its original position relative to the posts upon removal of the test loads. B5.2 Tests 5 and 6 The rails, post or system shall not suffer complete collapse and the system shall be capable of continuing to provide restraint. NOTE: Permanent deflection is permitted.

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AS 1657—2018 B6 REPORT In addition to the requirements of Appendix E, the report shall include the following information: Identification of guardrailing type.

(b)

The test loads applied, their location and the length of time they were applied.

(c)

Details of any failure, permanent deformation or deflection.

(d)

Whether the guardrailing passed or failed the test.

(e)

Detailed description, drawing or photograph of the force-transmitting device used.

(f)

Name and location of testing facility.

(g)

Date of test.

(h)

Name, position and qualifications of the person responsible for the test.

(i)

Signature of the person responsible for the test, including the date of test.

(j)

A reference to this test method, i.e. Appendix B, AS 1657.

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(a)

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AS 1657—2018

APPENDIX G

SELECTION OF STAIRWAYS, WALKWAYS AND FIXED LADDERS (Informative) G1 GENERAL The overall considerations and other issues associated with the selection of a means of access are summarized in Table G1 of this Appendix. The recommended guidelines for fall protection measures are summarized in Table H1 of Appendix H. G2 SELECTING A WALKWAY A level walkway or access from ground level is preferred where frequent access is required. Any control devices and other parts of equipment where frequent access is needed should be easily reached from this level.

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When considering the use of a walkway, the following points should be considered as a minimum: (a)

A level or sloping walkway can be the best solution where space permits.

(b)

A walkway facilitates easier movement of tools and equipment.

G3 SELECTING A STAIRWAY A stairway may be the best solution where— (a)

more than two risers are required; and

(b)

there is insufficient space for a walkway.

The angle of slope for a stairway ranges from 20° to 45°, with the preferred range being between 30° and 38°. G4 SELECTING A FIXED LADDER G4.1 General The selection of a ladder as a design solution for regular access should be avoided wherever possible due to the greater risk of falling, the greater physical effort required to climb and the restriction imposed on carrying tools and equipment. At high-risk locations, where the use of a ladder may not be appropriate, the design of the structure to which access is necessary should be modified to enable a safer means of access to be used. The following are typical conditions under which the use of a ladder may be appropriate: NOTE: Generally, at least two of the conditions need to be met before the use of a ladder can be considered appropriate.

(a)

Infrequent use of the ladder is foreseen. NOTE: When estimating the frequency of use, all phases of the life of the equipment to which access is necessary should be considered. Therefore, a ladder is not appropriate if frequent use during major maintenance tasks is foreseen.

(b)

The user will not be carrying any tools or other equipment by hand.

(c)

Only one user will be likely to be using the ladder at any one time.

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AS 1657—2018 (d)

The ladder is not intended to be used to evacuate injured persons.

(e)

The structure does not allow stairs or other basic means of access to be readily used (e.g. driver access to a tower crane).

(f)

The ladder is to be used predominantly for access to or from a location and not for the carrying out of any works.

The safety issues discussed in Paragraphs G4.2 to G4.5 also need to be considered when selecting a ladder. G4.2 Step-type ladders Step-type ladders should only be selected where stairs cannot be used because of space limitations. G4.3 Rung-type ladders (twin-stile ladders) Rung-type ladders are physically more difficult to use than step-type ladders or stairs. G4.4 Rung-type ladders (single-stile ladders)

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In addition to the considerations given in Table G1, the following issues are also associated with single-stile ladders: (a)

If the user slips and falls, there is a risk of impalement on the rung ends.

(b)

There is a danger of entangling clothing or safety equipment on the rungs.

(c)

They should be used only where a two-stile ladder cannot be used or installed (e.g. on telecommunications poles). NOTE: Single-stile ladders may not be suitable for use within confined spaces due to the risk of snagging or entanglement with rescue equipment.

G4.5 Individual-rung ladders (step-irons) Step-iron type ladders are physically more difficult to use than step-type or other rung-type ladders. In addition, step-iron type ladders can be difficult to access safely without specific additional provisions at the point of access (e.g. at the entrance hatch of a below-ground pit). Where another means of preventing access is not provided, the access point for a step-iron ladder needs to be locked off to prevent unauthorized use. G5 PREVENTION OF UNAUTHORIZED ACCESS Where access needs to be restricted, a lockable gate should be installed at the bottom of the ladder cage. If the ladder does not have a cage, a lockable hinged cover should be placed over the lowest 2.5 m of the ladder. A lockable non-climbable gate may also be used to prevent access to a walkway or stairway. Alternatively, the ladder, walkway or stairway should be located in a secured and restricted area. G6 FALL PROTECTION FROM LADDERS Appendix H provides guidelines for fall protection measures for various types of ladder installations.

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AS 1657—2018

www.standards.org.au

TABLE G1 SELECTION OF MEANS OF FIXED ACCESS Angle 0° to 3°

Type of access Level walkway (Section 5)

Considerations Frequent access required Suitable for use when light loads or tools need to be carried

3° to 20°

Sloping walkway (Section 5) preferred range is 3° to 10°

Suitable for use where there is a small vertical distance Good for emergency evacuations Suitable for two-way traffic Less physical effort required than stairs or ladders Transverse walkways to have a level walking surface

Stairways (straight flights) (Section 7) preferred range is 30° to 38°

Application

Slip resistance of walking surface important

Roof access

Preferable to a stair with 2 or 3 steps

Plant or maintenance access

Guardrailing conforming to Section 6 and incorporating handrails may be required Slip/fall protection required when angle of slope is 15° or greater

Access between service platforms Warehouse loading area access Access across unsafe areas Access across inclined roof areas

Width of walkway to be selected to suit expected use

Frequent access required

Not less than 2 risers

Roof access

Suitable for use when light loads or hand tools need to be carried

Maximum height of single flight is 4050 mm (18 risers at 225 mm)

Access to and between service platforms

Good for low to medium heights

Width and angle of stair to be selected to suit expected use

Access to service bays

Suitable for emergency evacuations Suitable for two way traffic

20° to 45°

Other issues

General plant access Vehicle operator access

Less physical effort required than ladders 60° to 70°

Step-type ladder (Section 7)

Periodic access 6 m maximum vertical distance between landings

The structure precludes other preferred methods of access

Mobile plant access

Consider need for restricted access or locked-off

Access to low level landings or platforms

Vehicle load access

Step-over for pipework or other obstructions (continued)

AS 1657:2018

 Standards Australia

Use if there is no need to carry loads or large tools

Ensure that persons using the ladder can only do so when facing the ladder

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AS 1657:2018

 Standards Australia

TABLE G1 (continued) Angle

Type of access

70° to 90° Rung-type ladder (twin-stiles) (Section 7) preferred range 70° to 75°

Considerations Infrequent access 6 m maximum vertical distance between landings There is a need to carry large tools or equipment

Other issues

Application

Generally intended for single person use

Access to plant or structure where limited space precludes other forms of access

Consider need for restricted access or locked-off

Mobile plant

Ladders exceeding 6 m in fall distance require a cage or fall protection device

Towers or masts

Not specifically intended for evacuation purposes Physically harder to use than other types of access 85° to 90° Rung-type ladder (single-stile) (Section 7)

Use only where other means of access cannot be used

Ladders exceeding 3.5 m in fall distance require some form of fall-arrest system

Consider 6 m maximum vertical distance between landings

Must be restricted access or locked off

Telecommunications masts

80° to 90° Individual rung-type ladder (step-irons) (Section 7) preferred range 80° to90°

Infrequent access Use only where other means of access cannot be used Used in near-vertical distance between landings 6 m maximum vertical distance between landings

Ladders exceeding 3.5 m in fall distance require some form of fall-arrest system

Access to plant or structure where space precludes other forms of access

Single person use only

Stormwater and sewerage access pits

Must be restricted access or locked off

Electricity cable pits

Used in a near-vertical slope only

Corrosion protection required

Provision required for safe access onto and off the ladder

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AS 1657:2018

APPENDIX H

FALL PROTECTION (Informative) H1 GENERAL The most effective fall protection occurs at the design stage by selecting the most appropriate means of access. The preferred means of access is a walkway. Where this is not possible, the designer should use the hierarchical approach specified in Section 2 of this Standard and Appendix G. Once the type of access system is selected, additional fall protection measures may be appropriate. Guidelines for fall protection are provided in Table H1 for the various types of access. The use of fall protection should take into consideration the skill level, competency and capability of the people using the system.

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H2 FALL PROTECTION ON LADDERS The provision of fall protection on a ladder is a complex issue that should be identified during the design stage after the installation and usage conditions are known. The following aspects should be considered: (a)

Design and configuration of the ladder installation.

(b)

Impact of site-specific conditions and surrounding environment.

(c)

Expected frequency of ladder use.

(d)

Controls and restrictions applied to ladder access.

(e)

The training and supervision of users at the particular location being considered.

(f)

Required rescue systems and the associated regular training and specialized equipment.

In general terms, a single fall protection system cannot be universally applied to all site locations and the selection of appropriate fall protection on ladders should be based on the site conditions and usage. H3 ALLOWANCE FOR HARNESS-BASED FALL-ARREST EQUIPMENT Harness-based equipment may be utilized in areas where a person is at high risk of falling while climbing a ladder and where other higher level controls are not possible. Where a harness-based fall-arrest equipment is used, the additional forces induced by the arresting of a falling person are significant and need to be considered in the design of the ladder system, and thus its rungs, stiles and fixings, as appropriate. Design loads for fall-arrest should be not less than 15 kN (ultimate) in accordance with the requirements of AS/NZS 1891 series. NOTES: 1

When using fall-arrest equipment on ladders, the need for rescue in the event of a fall should be considered. This also applies when retro-fitting equipment.

Where a fall-arrest device is fitted on the centre-line of a ladder, adequate clearance for the user’s feet should be provided.

www.standards.org.au

 Standards Australia

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AS 1657:2018

H4 APPLICATION OF FALL PROTECTION TO LADDERS Table H1 provides guidelines for the fall protection measures applicable to various installations. In Table H1 the term ‘fall distance’ refers to the distance from the person’s feet to the lowest point to which it is likely that they could fall. Determination of the lowest point should include the possibility of falling to a lower level than the base of the ladder.

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Where a fall-arrest system is specified it should comply with the relevant parts of AS/NZS 1891 series.

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AS 1657—2018 www.standards.org.au

TABLE H1 GUIDELINES FOR FALL PROTECTION MEASURES Fall protection for a fall distance of Angle

Type of access

Platforms and landings 0 m to 3.5 m

>3.5 m to 6 m

Other measures

>6 m

—

Not required

Slip resistance of walking surface important

—

Not required

Guardrailing conforming to Section 6 and incorporating handrails may be required

—

Landings may be required at regular intervals for steep (>15°) walkways

Guardrailing conforming to Section 6 and incorporating handrails may be required Slip/fall protection required at 18 m centres when angle of slope is 15° or greater (see Clause 5.4.2)

—

Landings are required at regular intervals for stairways

Maximum height of single flight is 4050 mm (18 risers at 225 mm) A means of preventing a person falling more than 36 risers to be provided (see Clause 7.2.2)

Restricted access or locked-off Three (3) points of contact when climbing Landings at not more than 6 m vertical distance Handrails fitted to ladder Side screens fitted to ladder

Maximum 6 m vertical distance between landings Provide change of direction, or stagger, or other protection (e.g. barrier, or 1.5 m landing length)

Ensure that persons using the ladder can only do so when facing the ladder Provide warning signs Provide other controls as required, based on site hazards, ladder configuration and frequency of use

—

4.5 m maximum vertical distance between landings for rung-type ladders at 75° to 90°

0° to 3°

Level walkway (Section 5)

—

≥3° to 12°

Sloping walkway (Section 5) preferred range is 3° to 10°

—

≥12° to 20°

Sloping walkway (Section 5)

≥20° to 45°

Stairways— straight flights (Section 7) preferred range is 30° to 38°

60° to 70°

Step-type ladder (Section 7)

Three (3) points of contact Three (3) when climbing, and points of handrails fitted to ladder contact when climbing, and handrails fitted to ladder

6 m maximum vertical distance between landings for other ladders

(continued)

AS 1657:2018

Landings are also required at regular intervals for walkways and stairways

Platforms and landings (Section 4)

 Standards Australia

Refer to Sections 4 and 7 for minimum lengths and other requirements

0° to 3°

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AS 1657:2018

 Standards Australia

TABLE H1 (continued) Fall protection for a fall distance of Angle

Type of access 0 m to 3.5 m

>3.5 m to 6 m

>6 m

Platforms and landings

Other measures

Rung-type ladder (twin-stiles) (Section 7) preferred range 70° to 75°

Three (3) points of contact when climbing

Restricted access or locked-off Three (3) points of contact when climbing Landings at not more than 6 m vertical distance A ladder cage or a harnessbased fall-arrest system

Maximum 6 m vertical distance between landings Provide change of direction or stagger, or other protection (e.g. barrier or 1.5 m landing length)

Provide warning signs Provide other controls as required, based on site hazards, ladder configuration and frequency of use

≥75° to 90°

Rung-type ladder (twin-stiles) (Section 7)

Three (3) points of contact when climbing

Restricted access or locked-off Three (3) points of contact when climbing Landings at not more than 4.5 m vertical distance or A ladder cage or a harnessbased fall-arrest system

Restricted access or locked-off Three (3) points of contact when climbing Landings at not more than 4.5 m vertical distance A ladder cage or a harnessbased fall-arrest system

Maximum 4.5 m vertical distance between landings Provide change of direction or stagger, or other protection (e.g. barrier or 1.5 m landing length)

Provide warning signs Provide other controls as required, based on site hazards, ladder configuration and frequency of use

85° to 90°

Rung-type ladder (single-stile) (Section 7)

Restricted access or locked-off Three (3) points of contact when climbing

Restricted access or locked-off Three (3) points of contact when climbing A harness-based fall-arrest system

Restricted access or locked-off Three (3) points of contact when climbing Landings at not more than 6 m vertical distance A harness-based fall-arrest system

Maximum 6 m vertical distance between landings Provide change of direction or stagger, or other protection (e.g. barrier or 1.5 m landing length)

Provide warning signs Provide other controls as required, based on site hazards, ladder configuration and frequency of use

≥70° to 75°

(continued) www.standards.org.au Bullivants | Page 121 of 692

AS 1657—2018 www.standards.org.au

TABLE H1 (continued) Fall protection for a fall distance of Angle 80° to 90°

Type of access Individual rungtype ladder (stepirons) (Section 7) preferred range 80° to 90°

0 m to 3.5 m

>3.5 m to 6 m

>6 m

Restricted access or locked-off Three (3) points of contact when climbing

Restricted access or locked-off Three (3) points of contact when climbing A ladder cage or a harnessbased fall-arrest system

Restricted access or locked-off Three (3) points of contact when climbing Landings at not more than 6 m vertical distance A ladder cage or a harnessbased fall-arrest system

Platforms and landings

Other measures

Maximum 6 m vertical distance between landings Provide change of direction or stagger, or other protection (e.g. barrier or 1.5 m landing length)

Provisions required for safe access onto and off the ladder Provide warning signs Provide other controls as required, based on site hazards, ladder configuration and frequency of use

NOTES: 1

Fall protection while climbing a fixed ladder may take the form of— (a) three (3) points of contact; (b) side screens (step-type ladders only); 89

Other appropriate controls for safe access by fixed ladders (as determined by a risk assessment) may include— (a) adopting another form of access other than the ladder (e.g. MEWP or scaffolding); (b) a first man up climbing process; (c) warning signs; (d) a means of controlling access to the ladder such as a locked room or restricted area; (e) gates, such as chain gates; (f)

a locked cover over the bottom rungs; and

(g) a combination of these controls.

AS 1657:2018

 Standards Australia

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AS 1657—2018

APPENDIX I

SAFE LADDER DESIGN, INSTALLATION AND USE (Informative) I1 SCOPE This Appendix sets out design, fabrication and installation considerations for ladders, to improve their safety and reduce the likelihood of injury to users. I2 TRANSITION TO THE TOP LANDING

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Transitions to the top landing should consider the following aspects, as applicable: (a)

Step-type ladders should incorporate continuous handrails from the base all the way the landing, so that the user does not have to let go on the way up (see Figure I1).

(b)

Step-type ladder designs that terminate the handrails at vertical stanchions should be avoided, since there is the need for the user to let go and re-engage at the highest point of the ladder, which may lead to a fall (see Figure I2).

(c)

The extended vertical stiles on vertical rung ladders should incorporate ‘D’ shaped handrails, to assist the user during access and egress (see Figure I3).

(d)

Inclined rung ladders should not have additional handrails built into the front of the ladder. These would serve to move the body’s centre of gravity backward and may lead to a fall (see Figure I4).

FIGURE I1 CORRECT HANDRAIL DETAIL AT TOP OF STEP-TYPE LADDER

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AS 1657—2018

FIGURE I2 INCORRECT HANDRAIL AT TOP OF STEP-TYPE LADDER

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600 mm

450 mm 1m

FIGURE I3 CORRECT HANDRAIL DETAIL AT TOP OF VERTICAL LADDER

FIGURE I4 HANDRAIL DETAIL AT TOP OF INCLINED LADDER

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AS 1657—2018

I3 TWIN-STILE RUNG-TYPE LADDERS—RUNG SHAPES The cross-sectional shape of a rung should be designed so that the surface area is maximized for a person’s foot to stand on. The shape of the rung should also be suitable for a person to grip while climbing the ladder. All corners should be rounded. The surface should be dimpled, knurled or treated to reduce slip. The maximum cross-sectional width of the rung should be 65 mm, and the maximum height 45 mm. The minimum cross-sectional width and height should be 20 mm. I4 TWIN-STILE RUNG-TYPE LADDERS—RUNG CONSIDERATIONS The rungs should be spaced equally in a rung ladder, with any variation in accordance with this Standard, recognizing that it is preferable to have all risers equidistant to reduce the likelihood of injury (see Figure 7.6). The top rung should be level with the landing platform, and the opening between the top rung and the landing should be closed off so as to provide a level surface to stand on (see Figure 7.12).

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If an opening is provided between the top rung and the landing, then this opening should be adjacent to the rung, and should be between 50 mm and 100 mm, so as to provide adequate spacing for the user to grip the top rung (see Figure 7.12). The area at the base of the ladder should be clear of any obstructions, and the fixing method should not obstruct a person’s foot at the base of the ladder. I5 STEP-TYPE LADDERS—TREAD SPACING The treads should be spaced equally in a step-type ladder, with any variation in accordance with this Standard, recognizing that it is preferable to have all risers equidistant to reduce the likelihood of injury (see Figure 7.4). The tread spacings should be not greater than 300 mm for a ladder height of up to 1 m, and between 250 mm and 300 mm for ladder heights exceeding 1 m. The top tread should be level with the landing platform, and the opening between the top rung and the landing should be closed off so as to provide a level surface to stand on, and a surface which a person cannot fall through. I6 LADDER CAGES Refer to Appendix H for the key considerations associated with the installation of ladder cage systems. In addition to the requirements of this Standard, the use of ladder cages should be considered for the ladder installations as indicated in Table H1, Appendix H. I7 HARNESS-BASED FALL PROTECTION FOR LADDERS Appendix H provides key considerations associated with the installation of harness-based fall protection systems. In addition to the requirements of this Standard, the use of harness-based fall protection systems should be considered for the ladder installations as indicated in Table H1, Appendix H.

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AS 1657—2018

I8 TOP AND BOTTOM LADDER LANDINGS The landing at the top and bottom of a rung ladder or step-type ladder should be level (within a range of 0° to 3°) and flat, with a landing area of not less than 900 mm long from the front of the ladder, and not less than 600 mm wide (see Figure I5). Installing a ladder directly onto an uneven surface such as a roof sheet may introduce a slip and trip hazard at the top and bottom of a ladder. This hazard should be eliminated by providing a level landing surface.

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900 mm min.

70 °

(a)

600 mm min.

(b)

FIGURE I5 TYPICAL LANDING DETAILS FOR ROOF ACCESS LADDERS

I9 INTERMEDIATE LANDING PLATFORMS In addition to the requirements of this Standard, the use of intermediate platforms and landings should be considered for the ladder installations as indicated in Table H1, Appendix H. An intermediate landing platform (Figure I6) performs a number of purposes, as follows: (a)

It limits the distance that a person would fall.

(b)

It provides an area for a person to rest whilst climbing to the top of a ladder since climbing a ladder requires significant physical exertion.

(c)

It provides an area for a person to lay down tools and equipment.

An intermediate landing platform should be placed as close as possible to the midway point between the bottom and top of a ladder system, or at equally spaced intervals for multiple landings, and should be of a suitable size to meet the requirements of this Standard.

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AS 1657—2018

Where space constraints limit the size of the intermediate landing, it is preferable to use a reduced landing platform size rather than no landing platform at all. This reduction in size should be subject to a risk assessment and result in a better control measure than an alternative side-mounted rest platform or a harness-based fall protection system. A side-mounted rest platform will not provide the benefits of Items (a) and (c) above, and should only be used where space constraints preclude the installation of an intermediate landing platform. Ladders that have side-mounted rest platforms should incorporate a harness-based fall-arrest system to limit the fall distance.

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2000 min.

6000

DIMENSIONS IN MILLIMETRES

FIGURE I6 LADDER CAGE DETAIL AT INTERMEDIATE LANDING

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AS 1657—2018

APPENDIX J

ROOF ACCESS (Informative) J1 GENERAL Where permanent access to the roof is required for the purposes of routine equipment or building maintenance activities, the information given in this Appendix should be considered. Where access to fragile, brittle or otherwise non-trafficable roofs is required, continuous walkways, platforms and guardrails should be provided. J2 ACCESS TO A ROOF J2.1 Internal access

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The preferred means of access is an internal access door. Where it is not feasible to provide an access door, an access hatch should be provided. Such a hatch should be provided with— (a)

guardrail protection on three sides; and

(b)

access provisions that conform to the requirements of Clause 7.4.8.3.

J2.2 Access from roof edge Guardrailing should be provided for a minimum distance of 2000 mm on either side of the entry point where a fall hazard exists. A self-closing gate, opening inwards towards the roof, should be installed between the guardrails at the point of entry to the roof. There should be a landing of not less than 600 mm × 600 mm at the top of the stair or ladder, to permit the gate to be opened without risk of falling (see Figure J1).

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AS 1657:2018

 Standards Australia

Roof access walkway

Guardrail system with handrail

Self- closing gate opening away from stair or ladder

600 min. landing at the top of stair or landing 96

Guardrailing not shown in this area for clarity Guardrailing to extend 2000 min. from edge of roof

Access stair or ladder Edge of roof

www.standards.org.au

DIMENSIONS IN MILLIMETRES

FIGURE J1 TYPICAL MEANS OF ACCESS TO A ROOF FROM ROOF EDGE

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AS 1657—2018

J3 GUARDRAILING Although some roofs may be suitable for access without provision of special walkways and platforms, specific locations may require handrails or guardrailing, particularly near the perimeter of the roof. Other areas (e.g. skylights and lightwells) may also require guardrailing. Where tools or equipment could slide or roll off the roof and fall onto persons beneath, a toeboard conforming to Clauses 5.5 and 6.1.2 should be fitted. Where the roof slope is 12° or greater, additional guardrailing conforming to Section 6 should be provided, in order to prevent a person, tools or equipment from sliding below the midrail (see Figures J2 and J3). This protection may take the form of infill, an additional rail, or vertical posts. If a toeboard is installed as part of the guardrailing, the requirements of Clause 6.1.2 will apply. Where the roof slope is 25° or greater, the height of the guardrail, measured vertically above the roof surface, should be not less than 1200 mm.

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Top of handrail

900 mm min.

Toeboard (where required)

Horizontal walking sur face ( 0 ° to 3°)

Angle of slope ≥ 12 °

FIGURE J2 INSTALLATION OF GUARDRAILING ON THE SIDE OF A TRANSVERSE WALKWAY WHERE THE ANGLE OF SLOPE IS 12° OR GREATER

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AS 1657:2018

Top rail

450 ma x. between top rail and intermediate rail

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Intermediate rail

900 -1200 (Paragraph J3)

Bottom rail or suitable infill

250 ma x. between intermediate rails

Toeboard ( where required)

250 ma x. between roof sur face and between toeboard and bottom rail

Roof slope (12 ° or greater)

DIMENSIONS IN MILLIMETRES

FIGURE J3 INSTALLATION OF GUARDRAILING AT THE EDGE OF ROOF WHERE THE ROOF SLOPE IS 12° OR GREATER

 Standards Australia

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AS 1666.1—2009

Australian Standard® Wire-rope slings Part 1: Product specification

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AS 1666.1—2009 PREFACE This Standard was prepared by the Standards Australia Committee ME-025 Lifting Tackle, to supersede AS 1666.1—1995. The other Standard in this series covering wire-rope slings is AS 1666.2, Wire-rope slings, Part 2: Care and use. The objective of this Standard is to provide a specification for wire rope slings that ensures safety and fitness for purpose. It is for reference by manufacturers, importers, users and regulators. This edition takes cognizance of EN 13414-1:2003, Steel wire rope slings—Safety, Part 1: Slings for general lifting service, and includes the following changes: (a)

Revision of definition of working load limit (WLL).

(b)

Deletion of safe working load (SWL) from any part of the Standard.

The terms ‘normative’ and ‘informative’ have been used in this Standard to define the application of the appendix to which they apply. A ‘normative’ appendix is an integral part of a Standard, whereas an ‘informative’ appendix is only for information and guidance.

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Statements expressed in mandatory terms in notes to tables and figures are deemed to be requirements of this Standard.

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AS 1666.1—2009 3.27 Sling A wire rope, assembled with or without components or fittings (e.g., ferrules, thimbles, links, hooks or eye) at each end, for lifting purposes. See Appendix B for description and illustration of types of slings. 3.28 Sling assembly An assembly of one or more wire-rope sling legs, including any components that are appropriate to the intended use. 3.29 Sling leg The wire-rope part of a sling assembly having a termination at each end. 3.30 Soft eye An eye formed without a thimble. 3.31 Strand A number of wires in one or more layers laid helically around a central wire or fibre core. 3.32 Strength The breaking force of a sling.

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3.33 Stud-end swage fitting A swage fitting with a threaded shank that is used to connect with another fitting or anchorage (see Figure 6).

FIGURE 6 STUD-END SWAGE FITTING

3.34 Swage fitting A fitting into which the end of a wire rope can be inserted and then permanently attached by cold pressing (i.e., swaging) the shank onto the wire rope. 3.35 Thimble eye An eye formed around a thimble (see Figure B1, Appendix B). 3.36 Tuck A single strand, where it is passed under one or more strands in a wire rope. 3.37 Turn-back eye A ferrule-secured eye in which the rope as a whole is bent to form an eye (see Figure 7).

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AS 1666.1—2009

FIGURE 7 TURN-BACK EYES

3.38 Working load limit (WLL)

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The maximum load that may be applied to the sling, in tension under general conditions of use. The working load limit may be changed for the particular application (see AS 1666.2). 4 MATERIALS 4.1 Components Wire rope shall comply with Clause 4.2. End fittings shall comply with Clause 4.3. Other components shall comply with any relevant Australian Standard or, if there is no relevant Australian Standard, with the intent of this Standard. 4.2 Wire rope Wire rope for the manufacture of slings shall be unused steel-wire rope in an as-new condition, complying with AS 3569 or of another construction, tensile grade or size for which the sling manufacturer has demonstrated the ability to comply with the performance requirements of this Standard. This Standard does not preclude the use of stainless steel wire rope, providing it meets the intent of this Standard.

Not Bullivants Policy

The selection of wire rope for a sling involves a number of considerations, including the manner in which the sling is to be used, such as the following: (a)

Where the sling is to be reeved, a flexible construction will be advantageous.

(b)

Where the sling is subjected to abrasion, a suitable construction should be used.

(c)

Where the sling is subjected to high temperatures, the sling manufacturer should be advised of the magnitude of such temperatures and the expected duration at these temperatures. A suitable construction and appropriate deration shall then be established. Wire rope with a wire (rope or strand) core should be chosen for such applications.

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AS 1666.1—2009 5.3 Dimensions

5.3.1

Tolerance on effective lengths

The tolerance on the effective length of slings measured prior to any proof loading, unless otherwise specified, shall comply with one of the following: (a)

For hand-spliced slings and slings with ferrule-secured fittings, ±2 rope diameters.

(b)

For slings with swage fittings or poured sockets, ±1 rope diameter.

5.3.2

Joints

Where a double-part sling is mechanically joined, two ferrules shall be applied to the joint at a spacing of not less than 6 rope diameters.

5.3.3

Internal length of soft eyes

For general use, the internal length of soft eyes in their natural unloaded shape should be not less than 12 times the diameter of the rope. For specified applications, the internal length of soft eyes in their natural unloaded shape should be not less than three times the width of the support (e.g., width of hook, diameter of supporting pin).

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5.3.4

Length of wire-rope leg

The length of sling legs shall comply with the following: (a)

Ferrule-secured sling legs shall have a distance between the ferrules securing the eyes of the sling leg of not less than 12 rope diameters. For general use, the effective length of double-part ferrule-secured sling legs shall be not less than 30 rope diameters. The effective length of single-part ferrule-secured sling legs shall be not less than— (i)

thimble-reinforced eyes ................................................. 36 rope diameters; and

(ii)

with soft eyes ...................................................................... 46 rope diameters.

(b)

Hand-spliced sling legs shall have an effective length (with or without a thimble reinforcement) of not less than 70 rope diameters.

5.3.5

Effective length of endless slings

The effective length of endless slings as defined by Figure B1 (g) of Appendix B shall be not less than 25 rope diameters. 5.4 Thimbles Where a component (link, shackle, hook or similar) is permanently attached to a sling leg, the eye of the sling leg to which the component is attached shall be thimble-reinforced. Each thimble in a sling shall comply with AS 1138 and be adequate for the strength of the wire rope used in the sling. The size of any thimble in a sling should be appropriate for the diameter of the rope. For double-part sling legs, a larger thimble than that appropriate for the diameter of the rope as a single-part sling should be used. The rope shall fit tightly around the thimble, to minimize movement of the thimble in the eye. The distance between the end of the ferrule adjacent to the thimble and the point of the thimble shall be not less than half the diameter of the rope. 5.5 Seizing Where it is necessary to seize the ends of rope to prevent unravelling, the length of each seizing shall be not less than the diameter of the rope.

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AS 1666.1—2009 5.6 Serving The length of wire rope around the crown of a thimble may require serving to avoid displacement of strands. The portions of a sling that contain wire ends or the full length of hand splicing should be neatly and effectively served to give protection to users. 5.7 Terminations

5.7.1

General

Terminations shall be designed by a competent person. End fittings shall be fitted in accordance with the appropriate Standard or manufacturer’s instructions. NOTE: For example, matching of termination type and size with the rope size and die size.

5.7.2

Ferrule-secured eyes

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Pressing of the ferrule and removal of the fins shall be in accordance with the ferrule-secured system designer’s instructions. Ferrules shall have dimensions that will enable a successful pressing or swaging operation, so that the termination formed by the ferrule complies with Clause 7.3. Ferrule-secured eye terminations of the turn-back and flemish types shall be a matching size to the wire rope and die as specified by the ferrule manufacturer. After completing the pressing operation, the correct position of the end of the rope shall be positively ascertained. For turn-back eyes, the tail of the rope shall protrude beyond the ferrule (see Figure 7). The tail should protrude beyond the ferrule by no more than one half of the rope diameter. In the particular case of oval ferrules with tapered ends used in the securing of the turn-back eye or endless loop where the rope end is contained within the ferrule, the ferrulesecured system designer shall provide means whereby the position of the rope end before and after pressing can be ascertained. This shall not include verification by marking the rope. Only the parallel portion of a ferrule shall be considered loadbearing. For turn-back eyes all fins resulting from the pressing operation shall be removed. Any fins shall not be pressed back into the ferrule.

5.7.3

Flemish eyes

This Standard only covers the manufacture of flemish eyes manufactured from six- or eightround-strand ropes with a core of wire rope or wire strand. The rope shall be unlaid into two parts, the core being assigned to one of the parts. The unlaid length shall be determined by the length of the eye to be formed. Both groups of strands shall be laid together again in opposite directions in such a manner that a balanced distribution of the load is ensured when the rope is loaded. High strands are not permissible.

5.7.4

Hand-spliced eyes

Hand-spliced eyes shall comply with the relevant requirements of AS 2759. Care shall be taken to ensure that splices are well made and tightly drawn. Hand-spliced eyes may be seized.

5.7.5

Poured sockets

Poured sockets (see also Clauses 4.3.2 and 8.2) shall have dimensions generally in accordance with BS 463.1, BS 463.2 or Type A or B as specified by USA Spec RR-S-550D. The breaking load of sockets shall exceed the minimum breaking load of Grade 1770 steel- core wire rope of a size for which they are made.

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AS 1666.1—2009 Poured sockets shall be fitted in accordance with AS 2759. Where resin compounds are used to attach poured sockets, the resin shall be within its expiry date and the socketing shall be performed in accordance with the resin manufacturer’s instructions.

5.7.6

Swage fittings

Swage fittings shall be provided with instructions giving the correct method of pressing onto rope. Swage fittings shall only be connected to a wire rope having a wire-rope core. Swage fittings shall be a matching size for the rope and be swaged in accordance with the manufacturer’s specifications. 5.8 Grommets Each grommet shall be constructed from one continuous length of strand or wire rope. The single length of strand or wire rope shall be laid up in construction six times over one for sixstrand ropes and eight times over one for eight-strand ropes. The grommet shall contain one tuck diametrically opposite to the core butt position. 5.9 Double-part sling legs The splice of a double-part wire-rope sling leg shall be adjacent to, but clear of, the eye in the finished sling leg and include two or more ferrules that are spaced at not less than six rope diameters from one another (see Figures B1 (b) (i) to B1 (b) (iv).

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The following requirements shall apply to any seizing of double-part wire-rope sling legs: (a)

The two parts of double-part sling legs shall be parallel to each other. Seizing shall retain the two parts of the double-part sling leg together. A central seizing equal in length to three times the diameter of the single part shall be provided, or seizings shall be provided at intervals of not more than 72 times the diameter of the single part.

(b)

Thimbles shall be seized in the throat of the rope by means of annealed quality-steel seven-wire strand, or other suitable material that is appropriate for the diameter of the wire rope, and the overall length of each such seizing shall be not less than six diameters of the single part of the wire rope.

(c)

Seizings shall be tightly drawn, neatly made and free from projections that are liable to cause injury during handling.

5.10 Sling assemblies

5.10.1

Single-leg slings

Each single-leg sling shall comprise a single-leg, with or without components attached.

5.10.2

Two-leg slings

Each two-leg sling shall comprise a master link or a master link assembly that has a capacity to accept the legs.

5.10.3

Three-leg slings

The legs of three-leg slings shall be inter-connected by the following arrangements: (a)

Attaching each of the three sling legs directly to a master link.

(b)

Using a master link assembly with two intermediate links and attaching two of the sling legs directly to one of the intermediate links and the other sling leg directly to the other intermediate link.

5.10.4

Four-leg slings

Four-leg slings shall comprise two two-leg assemblies, each with an intermediate ring or link. A main ring, link or shackle shall join the two intermediate rings or links.

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AS 1666.1—2009 5.10.5

Overcrowding

Intermediate links shall be of a size that will not cause overcrowding. Overcrowding is considered to occur where an included angle of 60° cannot be accommodated.

5.10.6

Links

The welding and heat treatment of links shall be completed before the wire-rope legs are attached. Lifting links shall comply with AS 3776. NOTE: Various types of sling assembly are illustrated in Appendix B.

6 WORKING LOAD LIMIT (WLL) 6.1 Single-leg sling The WLL of a single-leg sling shall be calculated as follows: WLL =

P×R t

5 × 9.81

where

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WLL = working load limit P

= minimum breaking force of rope as specified for the rope in AS 3569, in kilonewtons (see Clause 4.2)

= reduction factor, as follows: Type of termination

Diameter of rope mm

Factor Rt

Double-part slings and grommets

All

1.5

≤80 >80 ≤20 >20

0.95 0.9 0.9 0.8

Poured socket

All

Swaged fitting

All

Ferrule-secured splice Hand-spliced eye

6.2 Multi-leg slings The WLL of multi-leg slings shall be not more than F times the WLL of the weakest leg, where F is the following: Angle between opposite legs ≤60° >60° ≤90° >90° ≤120°

F 1.73 1.41 1.0

7 MECHANICAL PROPERTIES 7.1 Permanent distortion The sling shall be tested in accordance with Clause 10.1 and the requirements of Clause 10.2 shall be met.

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AS 1666.1—2009 7.2 Strength Each wire rope leg of a sling shall be capable of supporting a force equal to five times the WLL of the leg (or single-leg sling) as specified in Clause 6 applied under the conditions specified in Appendix C. Interfacing components shall comply with relevant Standards (see Note 3). NOTES: 1

This Standard only considers general conditions of use.

Where a sling leg is used for tensioning or staying, the strength may differ.

Standards for interfacing components are included in the list of Standards for lifting systems given in Appendix E.

Except for rope, in event of failure due to overloading, the failure of any component shall be in a ductile manner. 7.3 Performance of terminations Terminations shall be capable of supporting a force equal to the minimum breaking force of the rope multiplied by the reduction factor shown in Clause 6.1. 8 MARKING

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8.1 General

NB: Date not required

Each sling and each sling assembly shall be permanently and legibly marked or tagged as near as possible to the upper terminal fitting with the following information: (a)

Manufacturer’s identification.

(b)

WLL for single-leg slings, or WLLs for applicable angles of multi-leg slings.

(c)

Identification marking to correlate the sling to the test certificate. For multiple identical slings, the batch identification number meets this requirement.

8.2 Poured sockets In addition to the requirements of Clause 8.1, each poured socket (see also Clauses 4.3.2 and 5.7.5) shall be marked with an identification number of the socket, together with an identification of the manufacturer or supplier. Manufacturers making a statement of compliance with this Standard shall ensure that such compliance is capable of being verified. NOTE: Typical marking tags that comply with Clause 8.1 are illustrated in Figure 8.

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AS 1666.1—2009

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FIGURE 8

TYPICAL MARKING TAGS

9 TYPE TESTING OF MECHANICAL PROPERTIES Compliance of each design with the requirements of Clause 6 and Clause 7 shall be demonstrated. NOTES: 1

The test of each design is known as the type test, which determines the adequacy of the design for achieving the required performance.

Each change in manufacturing process, grade of material, construction of rope, design and size necessitates separate type testing, to demonstrate compliance with the requirements of Clause 6 and Clause 7.

In addition to type testing, effective quality control necessitates systematic testing of each lot or batch to ensure continuing compliance with the requirements of Clause 6 and Clause 7.

Means for demonstrating compliance with this Standard are given in Appendix D.

10 PROOF TEST 10.1 Proof loading Each leg of a sling (including each single-leg sling) shall be subjected to a proof force that is not less than twice the WLL of the leg (or single-leg sling) applied under the conditions specified in Appendix C, except under the following circumstance, in which case a proof test of 1.5 times the WLL of the leg shall be applied: (a) Where a thimble is fitted together with a permanently attached interfacing component as defined in applicable Standards. (b)

Where the WLL of a sling leg exceeds 50 t.

NOTES: 1

The exception of Item (a) above is to assist in cases where a proof load factor of two will cause a distortion of a thimble.

Standards for interfacing components are included in the list of Standards for lifting systems given in Appendix E.

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AS 1666.1—2009 Each master link or master-link assembly shall be proof-loaded to twice the WLL of the sling assembly. 10.2 Requirements The sling shall— (a)

withstand the application of the proof force, without sustaining damage that may affect its intended function or safety; and

(b)

after testing, be free from any deleterious permanent set or defects that can be detected by visual inspection.

A competent person (see Clause 3.4) shall be satisfied that these requirements have been complied with. 10.3 Test certificate

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The proof testing shall be recorded on a test certificate, which shall bear the following information: (a)

Description of the sling (including assembly, components, type, size and effective length).

(b)

Construction and grade of the wire rope.

(c)

WLL.

(d)

Proof force(s).

(e)

Date of proof test.

(f)

Number tested.

(g)

Identification marking correlating with the sling.

(h)

A declaration that the slings comply with this Standard.

(i)

The name of the manufacturer or supplier.

(j)

The name and address of the testing establishment.

(k)

The name of the signatory.

(l)

The type of certificate (e.g., NATA, certifying authority, supplier). NOTE: The manufacturer should retain an original test certificate for not less than 10 years.

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AS 1666.1—2009 APPENDIX E

STANDARDS FOR COMPONENTS USED IN LIFTING SYSTEMS (Informative)

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The following is a list of Australian Standards for components used in lifting systems: AS 1138

Thimbles for wire rope

1353 1353.1 1353.2

Flat synthetic-webbing slings Part 1: Product specification Part 2: Care and use

1380 1380.1 1380.2

Fibre-rope slings Part 1: Product specification Part 2: Care and use

1438 1438.1 1438.2

Wire-coil flat slings Part 1: Product specification Part 2: Care and use

1666 1666.1 1666.2

Wire-rope slings Part 1: Product specification Part 2: Care and use (this Standard)

2076

Wire-rope grips for non-lifting applications

2089

Sheave blocks for lifting purposes

2317

Collared eyebolts

2318

Swivels for lifting applications

2319

Rigging screws and turnbuckles

2321

Short-link chain for lifting purposes

2740

Wedge-type sockets

2741

Shackles

2759

Steel-wire rope—Use, operation and maintenance

2841

Galvanized steel wire strand

3569

Steel wire ropes

3585

Hooks for flat-webbing slings

3775 3775.1 3775.2

Chain slings—Grade T Part 1: Product specification Part 2: Care and use

3776

Lifting components for Grade T chains slings

3777

Shank hooks and large-eye hooks—Maximum 60 t

4142 4142.2

Fibre ropes Part 2: Three-strand hawser-laid and eight-strand plaited

4497 4497.1 4497.2

Round slings—Synthetic fibre Part 1: Product specification Part 2: Care and use

4991

Lifting devices

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AS 1666.2—2009

Australian Standard® Wire-rope slings Part 2: Care and use

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AS 1666.2—2009 (b)

repositioned in different orientations, to assist the lubricant to remain distributed through the wires in the rope; and

(c)

lubricated whenever the sling contains insufficient lubricant to protect the wires in the rope from corrosion (a loss of lubricant may occur during storage).

7 CARE DURING USE Slings are prone to damage. They are weakened by broken wires, corrosion, chemical attack, overheating, wear, physical abuse, overloading, kinking and flattening of eyes.

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Safety in the application and use of wire-rope slings can be achieved by taking the following precautions: (a)

Select materials and types of sling that are suitable for the application.

(b)

Examine slings prior to use.

(c)

Do not overload slings.

(d)

Do not abuse slings.

(e)

When applying a choke hitch, allow the angle of choke to form naturally, without being hammered.

(f)

Protect ropes against damage from sharp corners or projections around which they pass. Bends having a radius of less than the diameter of the rope will cause permanent damage to the rope.

(g)

Protect terminations against damage from sharp corners and projections.

(h)

Avoid loading terminations in a non-axial manner (see Item 9(j)).

8 LIMITATIONS FOR USE The following limitations apply to the use of slings and sling assemblies, typical examples of which are illustrated in Figures 1 to 13: (a)

Splices in ropes shall not be bent around corners or edges, whether sharp or curved and shall be in the free length of the sling.

(b)

The inside radius of any bend in a wire rope around a corner of a load (i.e. except at the point of reeving of choke hitches) shall be not less than— (i)

the rope diameter where the included angle of the bend in the rope is more than 90° five times the rope diameter where the included angle of the bend in the rope is not more than 90° [see Figure 1(b)].

FIGURE 1

MINIMUM INSIDE RADII OF WIRE ROPES

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AS 1666.2—2009

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(c)

Where an endless sling or a soft eye of a sling interfaces with a fitting— (i)

the supporting surface of the fitting shall have a diameter of not less than the rope diameter; and

(ii)

where the diameter of such a supporting surface is less than 1.5 rope diameters, the sling shall be derated by 25% in accordance with Item (m) of Clause 9.

(d)

Reeved slings shall not support a load while they have an angle of choke (nip angle) exceeding 120° (see Figure 2).

(e)

Where a two-leg sling or two single-leg slings are secured by a single-wrap choke hitch, the angle between the legs shall not exceed 45° (see Figure 7).

(f)

Where a two-leg sling or two single-leg slings are each wrapped twice around the load and secured by a choke hitch, the angle between the legs shall not exceed 60° (see Figure 8).

(g)

The angles between the legs of slings in a single-wrap basket hitch shall not exceed 45° (see Figure 9).

(h)

The angles between the legs of slings in a double-wrap basket hitch shall not exceed 60° (see Figure 10).

(i)

The angles from the vertical to each of the legs of multi-leg slings shall not exceed 60° (see Figures 11 to 13).

(j)

Where multi-leg slings are connected to a crane hook, they should be connected by an intermediate component so that the load is supported axially through the crane hook (see Figures 9 to 13).

(k)

A saddle of a hook should not support more than two sling legs.

(l)

The latch mechanism of a hook shall not support any force while the hook is supporting a load.

(m)

Use of slings is limited by the temperature and provisions of Table 1 shall apply.

Account should be taken of the maximum temperature that can be reached by the wire rope sling in service. This is difficult in practice but underestimation of the temperature should be avoided. Table 1 summarizes the necessary de-rated working load limits of a sling due to temperature, taking into account the type of rope termination, the ferrule material and the core of the rope. The use of wire rope slings within the permissible temperature ranges given in Table 1 does not require any permanent reduction in working load limit when the rope is returned to ambient temperature. Wire rope slings will not be adversely affected by temperatures down to −40°C; therefore, reduction from the working load limit is necessary on this account. Where wire rope slings are to be used at temperatures below −40°C the manufacturer should be consulted.

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AS 1666.2—2009 TABLE 1

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DE-RATED WORKING LOAD LIMIT (WLL) OF SLINGS DUE TO TEMPERATURE Termination type

Ferrule material

Rope core

Turn-back eye

Aluminium

Turn-back eye

De-rated working load limit expressed as % of WLL of the sling Temperature, T, °C 40<T≤100

100<T≤150

150<T≤200

200<T≤300

300<T≤400

400<T

Fibre

100

Do not use

Aluminium

Steel

100

Do not use

Flemish eye

Steel

Fibre

100

Do not use

Flemish eye

Steel

100

Do not use

Hand splice

—

Fibre

100

Do not use

Hand splice

—

Steel

100

Do not use

FIGURE 2 USE OF PROTECTIVE PACKING

FIGURE 3 SIMPLE CHOKE HITCH AROUND A ROUND LOAD

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AS 1666.2—2009

FIGURE 12

THREE-LEG SLING

FIGURE 13 FOUR-LEG SLING

9 WORKING LOAD LIMIT (WLL) Slings shall not be used to lift a load that exceeds the WLL of the sling for the particular conditions of use. The WLL of the sling shall be consistent with the method of lift and reeving, and allow for any excessive dynamic load effects and any abnormal or severe working condition. The WLL of a sling assembly shall be calculated from the following equation: where

WLL = Rc × Rt × Ro × P/(5 × 9.81)

= factor for the particular configuration (see Table 2)

= factor for the particular termination (see Table 3)

= factor for the other derations that apply for the particular lift (see Items (b), (c), (j), (k) and (l) below).

= minimum breaking force as specified for the particular rope in AS 3569, in kilonewtons

Where the configuration is not covered by the label, users shall always consult a sling load chart. Appendix C gives sling load charts for slings fitted with ferrule-secured eyes. The WLL for each application of a wire-rope sling shall comply with the following: (a)

General use General conditions of use are equivalent to a group classification of crane mechanisms of M3 as specified in AS 1418.1. Under general conditions of use, the WLL of a sling is normally equal to the WLL.

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AS 1666.2—2009 (b)

Non-general use Under other than general conditions of use (e.g. severe conditions, hazardous conditions, directly supporting personnel), the WLL shall be determined by the group classification of crane mechanisms as specified in AS 1418.1 for the conditions of use that apply. Under specified or unusual conditions of use (e.g. a high-temperature environment, handling dangerous substances), the use of a derating that is greater than the relevant derating specified in AS 1418.1 may be required.

(c)

Engineered lifts Where an engineered lifting situation exists that uses slings that are designed for a special purpose, such as large slings that are individually designed and incorporated into an engineered lift, it may be acceptable to use lower factors of safety than those specified for general use under Item (a) above. NOTE: A guide for the design of engineered lifts is given in Appendix B.

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Where an engineered lift is employed, an appraisal shall be undertaken by a competent person, who shall consider both the lifting apparatus and the lifting procedure that is proposed. (d)

Grommet and double-part sling legs The WLL of each grommet (that is not a cable- laid grommet) and each double-part sling leg shall be in accordance with Table 2 and Table 3.

(e)

Non-vertically orientated leg of a sling The WLL of a non-vertically oriented leg of a sling shall allow for its inclination to the vertical.

(f)

Multi-leg slings The WLL of a general purpose multi-leg sling (i.e. a sling assembly comprising two or more legs) shall be not more than that calculated for only two of its legs to support a load having a symmetrical configuration with an included angle between the two legs of 60°. The WLL for a multi-leg sling having an included angle of 60° between the legs shall not be exceeded, even when the included angle between the legs is less than 60°. The included angle between the legs of a multi-leg sling shall not exceed 120°. The WLL of lifting components of a multi-leg sling shall be considered when determining the WLL of the sling assembly.

(g)

Reeved slings The WLL of reeved wire-rope slings shall be not more than x times the WLL of the wire rope, where— (i)

for round loads, x = 0.75; and

(ii)

for other than round loads, x = 0.5.

(h)

Sling assemblies Where components are attached to wire rope to make up sling assemblies, the WLL of each component shall be compatible with the WLL of the sling assembly and with the manner in which the component is used in the assembly.

(i)

Configuration Table 2 gives the factors (Rc) that shall be used to allow for particular configurations.

(j)

Non-axial loading The WLL of slings and end fittings shall be derated where they are loaded in a non-axial manner.

(k)

Dynamic loading Where a sling application involves unusual dynamic loading of the sling, the sling shall be derated.

(l)

Terminations Table 3 give the factors (Rt) that shall be used to allow for particular terminations.

(m)

Endless slings and soft eyes Except for reeving, where an endless sling or a soft eye of a sling is interfaced with a component of less than 1.5 rope diameters (but not less than one rope diameter, see Item (c)(i) of Clause 8), the sling shall be derated by 25%.

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AS 1666.2—2009 TABLE 3 FACTORS FOR TERMINATIONS (Rt) Diameter of rope

Factor

Double-part slings and grommets

All

1.5

Ferrule-secured splice

≤80

0.95

>80

0.9

≤20

0.9

>20

0.8

Poured socket

All

Swaged fitting

All

Type of termination

Hand-spliced eye

10 INSPECTION OF SLINGS

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A sling will eventually deteriorate as a result of abrasive wear, wire breaks, loss of lubrication, corrosion and consolidation of the core and rope strands. Damage is not always readily evident. The normal types of damage are described in Clause 11. Weakening effects are more serious on smaller sizes of rope than on larger sizes of rope because of the greater ratio between the perimeter and cross-sectional area. Good inspection practice will isolate causes of deterioration and enable the detection of damage to wire rope and end fittings. This can improve storage, handling and application practices. Advice on discarding of slings in given Clause 12. Slings in storage shall be regularly inspected for deterioration and, when necessary, withdrawn from use and discarded. Each sling shall be inspected prior to each use to ensure that it is in a safe condition. Slings used in circumstances, areas or atmospheres prone to acid, alkali, chemical or other damaging action shall be inspected for possible deterioration prior to re-use. Inspection shall give particular emphasis to— (a)

the presence and legibility of markings in accordance with AS 1666.1.

(b)

the loadbearing points;

(c)

examination of each strand along its length, opening the rope as much as practicable to enable examination of the surfaces of the strands towards the inside of the rope;

(d)

end fittings; and

(e)

attachments.

Periodic inspection shall be appropriate to the degree of utilization and working environment. Periodic inspection shall be conducted by a competent person and appropriate records shall be kept. NOTE: Wire rope slings constructed of stainless steel or other fatigue-prone materials may require periodic inspections at higher frequencies than expected for wire rope slings made of carbon steel complying with AS 1442.

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AS 1666.2—2009 11 TYPES OF DAMAGE

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Wire rope can be damaged in different ways and the resulting damage can take the forms of external wear, local abrasion, broken wires, internal wear, physical deterioration, corrosion, kinking and flattening of eyes, as follows: (a)

Severe overloading of wire ropes is evidenced by an increasing rate of fracture of the wires and excessive stretch under load accompanied by marked reduction in diameter.

(b)

External wear can be caused by dragging the sling over rough surfaces and is the most readily noticeable cause of weakness, particularly if a new sling is available for comparison. In the extreme, the strands become so worn that their outer faces are flattened and the outer wires severed. In normal use, some disarrangement or breakage of the wires on the outside of the sling is unavoidable and is not normally harmful unless extensive (see AS 2759).

(c)

Local abrasion, as distinct from external wear, can be caused by the passage of the sling over sharp edges whilst under tension and can cause a serious loss of strength. It is good economy to protect slings at points where excessive local abrasion can occur.

(d)

Cuts, bruises and similar damage can be internal as well as external. This type of damage is indicated by local rupturing or loosening of the wires or strands. It is caused by lack of care in use such as hammering of the slings and careless placement of the load.

(e)

Internal wear is caused by repeated flexing of the sling and by particles of grit picked up in service. Internal wear is accelerated by lack of lubrication and by corrosion.

(f)

Corrosion is caused by dampness and exposure to acids, alkalis, other chemicals, flue gases, industrial dusts, ashes and similar substances.

(g)

High temperatures, such as are found in foundries, steel works and like applications, reduce both the strength and the safety of a sling.

(h)

Distortion, permanent set or any physical deformation of end fittings, particularly at loadbearing points.

12 DISCARDING SLINGS Criteria for discarding wire rope because of wear or damage are given in AS 2759. It is difficult to define a standard of acceptance or rejection of a wire rope or wire-rope sling. There are no well-defined criteria for deciding between slings that are safe and those that are not, because any degree of safety depends upon the degree of deterioration of the rope and the severity of service to which the sling is subjected. Any decision whether or not to withdraw a sling from use shall be based on an assessment of the general condition of the sling. The effect of wear and mechanical damage is relatively greater with slings made from smaller diameter ropes, which would therefore require more rigid standards of acceptance. After examination, if any doubt exists about the safety of a sling, it shall be withdrawn from service. Slight damage to the outer wires of a wire rope may be disregarded. Serious damage of one strand or somewhat less serious damage to more than one strand however merits rejection of the sling. Slings with signs of detrimental corrosion shall be discarded. Slings that are known to have been subjected to heavy impact load or loaded in a kinked condition shall be destroyed and discarded. Where a sling is known to have been or is suspected of having been severely overloaded, it shall be discarded.

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AS 1666.2—2009 Where kinking is such that it creates a hazard in taking up loads, through possible hand injuries or causing unevenness or jerking during loading, the kinked slings shall be discarded. Slings shall be discarded where— sling markings are illegible (i.e., information on sling cannot be identified);

(b)

there is damage to upper or lower terminal fittings; or

(c)

there is damage to rope terminations.

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(a)

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AS/NZS 1891.1 :2020

Australian/New Zealand Standard ™

Personal equipment for work at height Part 1: Manufacturing requirements for full body combination and lower body harnesses

Originated in Australia as AS 1891-1976. Originated in New Zealand as NZS 1661:1962 and NZS 2253:1969. Revised and redesignated as AS/NZS 1891.1:2007. Second edition 2020.

© Standards Australia Limited/the Crown in right of New Zealand, administered by the New Zealand Standards Executive 2020 All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher, unless otherwise permitted under the Copyright Act 1968 (Cth) or the Copyright Act 1994 (New Zealand).

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AS/NZS 1891.1:2020

Section 2 2.1

Webbing, thread, rope and hardware

General

This Section specifies requirements for webbing, rope, thread and hardware used as a component of a harness. Natural fibres and materials, other than those meeting the requirements specified in Clause 2,2, shall not be used for load bearing components, but may be used for other purposes such as, but not limited to, wear protection, alignment or padding. All ancillary, non-load bearing components should be designed to be replaceable or last the life of the harness.

2.2 Webbing and thread 2.2.1 General All harness load bearing components which distribute force to the body and are in contact with it shall be made from webbing or material equivalent to webbing in respect of strength, durability and load transfer characteristics.

2.2.2 Design and construction Webbing shall be manufactured from high tenacity synthetic fibre. The width of the load transfer area of any load-bearing material at any point which distributes the load directly to the body shall not be less than 40 mm wide and shall remain substantially flat in regular use. The load transfer area is the section of the harness in contact with the body. Holes, rivets or eyelets shall not be used in load bearing webbing. Threads for sewing load bearing components shall be of a contrasting colour to the webbing. NOTE The thread should be manufactured from high tenacity synthetic fibre and have a melting point and chemical resistance equivalent to or superior to the material being sewn.

2.2.3 Performance requirements Loadbearing webbing shall be tested in accordance with Appendix A for resistance to degradation by either artificial light or daylight. When tested in accordance with Appendix A the minimum breaking strength of the three exposed samples shall be at l east 70 % of the mean of the breaking strength of the three unexposed samples.

2.3

Attachment hardware and adjusters

2.3.1 General All attachment hardware, and adjusters shall be as follows: (a)

Designed and tested ( i.e. type tested and routine tested as appropriate) to meet the applicable strength requirements for their application as specified in Clauses 2,3,3 to .2..3..5,.

( b)

Protected from corrosion in accordance with Clause 2,3,2.

(c)

Free from any material or manufacturing defects.

(d )

Designed to minimize damage to webbing.

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AS/NZS 1891.1:2020

2.3.2

Corrosion protection coatings test

Metal components shall be coated for corrosion protection and tested in accordance with ISO 9227, neutral salt spray (NSS) test, with 24 h testing + 1 h drying + 24 h testing + 1 h drying and examined within 90 s after drying. Following testing (a)

products with moving parts shall still function as designed; and

(b)

there shall be no loss of the protective coating which exposes underlying base material.

NOTE

Tarnishing and discolouration is acceptable.

2.3.3

Connectors

Connectors shall be in accordance with either (a)

ANSI/ASSP Z359.12; or

(b)

EN 362.

Connectors conforming with EN 362 shall also have a gate resistance (face and side) of 6 kN minimum. 2.3.4

D rings and O rings

D rings and O rings used as attachment hardware shall have a minimum capacity of 22 kN. Testing shall be in accordance with ANSI/ASSP Z359.12. Products being used to perform the same function as a D ring or O ring, manufactured from rigid material other than metal, shall meet the same requirements specified in Clauses 2.3.1 . .2....3..2. and this Clause 2.3.4. 2.3.5

Adjusters

Adjusters shall be designed (a)

such that they can be fastened only in the intended manner;

(b)

to withstand the loads transmitted as a result of the appropriate assembly test (see Appendices B to E as applicable ); and

(c)

to withstand, without permanent distortion, a load of 5 kN for 3 min when tested in accordance with the methodology specified in ANSI/ASSP Z359.12.

NOTE T he design of the adjuster should minimize "creep" of the harness under normal wearing, i.e. cyclic mild tensioning.

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AS/NZS 1891.1:2020

Section 3

Design and construction requirements

3.1

Common requirements

3.1.1

Fitment and adjustment

The harness shall be capable of adjustment to fit the wearer. The fitting and adjusting of the harness to the wearer shall be by means of adjusters. Adjusters shall not be located in such a position that any one adjuster could sustain the full load of a fall-arrest unless it has been designed and tested as attachment hardware. NOTE The design should be such that, when correctly fitted, there is no undue pressure on any sensitive part of the body during a fall-arrest or when a person is suspended after a fall.

3.1.2

Attachment points

Where two or more attachment points are present at any one of the designated positions on the harness they shall not impede the function of each other. Pole strap attachment points, where fitted, shall be placed on each side of a harness in the general area of the waist. Attachment points made by web loops designed to be used in isolation shall be capable of taking the full load for the criteria specified for that location on the harness (see Table 1.1). Attachment points made by web loops where two or more loops are designed to be brought together shall, when brought together as designed, be capable of taking the full load for the criteria specified for that location on the harness (see Table 1.1). Attachment hardware shall be secured to the harness so that the assembly is capable of taking the full load for the criteria specified for that location on the harness (see Table 1,1). 3.1.3 Adjusters When included, adjusters shall be used in harness design and construction in a manner that results in the following: (a )

Where separable they shall only be capable of being fastened in a manner which enables them to withstand their design load requirement.

(b)

They are connected to the harness so that they withstand the loads transmitted as a result of the appropriate harness assembly test.

3.1.4

Integral lanyard assembly or pole strap

Where a permanently attached lanyard assembly or pole strap is provided as an integral part of a harness the lanyard assembly or pole strap shall conform to AS 1891.S.

3.2

Full body harness

The full body harness shall comprise a single assembly enclosing shoulders, thighs and torso, which may include a combination of webbing, attachment points, adjusters or other components capable of adjustment to fit the wearer. The components shall be arranged and assembled to support the whole body of a person, manage the load applied to the body and prevent the wearer falling out of the harness during and after a fall-arrest. Typical full body harnesses are shown in Figure 3.1.

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AS /NZS 1891.1: 2 O 2 O

Attachment hardware

straps

Attachment hardware

Adjusters Front

Back (a) Harnesses without waist strap

,______ Centreline Shoulder straps

Attachment hardware

Front chest attachment point

Restraint attachment point Pole strap attachment points

Waist strap Front waist attachment point Front

Back ( b ) Harnesses with waist strap

Figure 3.1 - Examples of typical full body harnesses

3.3

Lower body harness

The lower body harness shall comprise a single assembly enclosing thighs and waist, which may include a combination of webbing, attachment points, adjusters or other components capable of adjustment to fit the wearer. The components shall be arranged and assembled to support the lower body of a person, manage the load applied to the body and prevent the wearer falling out of the harness during and after a fall-arrest. Typical lower body harnesses are shown in Figure 3.2.

AS/NZS 1891.1:2020

(a)

(b)

Figure 3.2 - Example of a typical lower body harness

3.4

Combination harness

The combination harness shall comprise a lower body harness that is connected to a removable upper body assembly. The upper body assembly shall not be designed or constructed to enable it to be used on its own as a harness. The upper body assembly shall comprise a single assembly which, when connected to a lower body harness, encloses the shoulders, thighs and torso which may include a combination of webbing, attachment points, adjusters or other components capable of adjustment to fit the wearer. The components shall be arranged and assembled to support the whole body of a person, manage the load applied to the body and prevent the wearer falling out of the harness during and after a fall-arrest.

AS/NZS 1891.1:2020

Section 5 5.1

Instructions and labelling

Instructions for use

The following shall be supplied with each harness and any separately supplied harness component covered by this Standard: (a)

Clear instructions for fitting, adjustment and use.

( b)

Advice that users consult AS/NZS 1891.4 for selection, use, maintenance and training requirements, and be competent in the use of equipment before beginning any tasks requiring its use.

(c)

The limitations of use of the equipment, and warning against making alterations or additions to it not agreed to by the manufacturer (e.g. combination harness upper and lower body component compatibility limitations).

(d )

Advice to minimize free-fall distance (maximum free-fall 2 m).

(e)

Advice to make certain any connection to a harness is checked before use.

(f )

A warning that if any part of an assembly is to be exposed to chemicals, e.g. cleaning materials or hazardous atmospheres, the user needs to consult the manufacturer to determine whether the part is suitable for continued use.

( g)

A warning that harnesses need to be removed from service and destroyed if a fall has been sustained.

( h)

The manufacturer's stated inspection and maintenance intervals and a reference to maintenance instructions.

(i)

Instruction that the maximum life of textile components of products covered by this standard is 10 years from the manufacturing date.

5.2

Labelling

5.2.1

General

Harnesses shall be clearly and permanently labelled with the following information: (a)

Manufacturer's name, trade name or trademark.

( b)

Serial number.

(c)

Model and type/Identification.

(d )

Standard number and year to which it conforms.

(e)

The purpose/use of each individual attachment point. This shall be achieved either by labelling each attachment point, or inclusion of information in the labelling of the harness.

(f )

The month and year of manufacture. NOTE

Facility may be provided for user marking of an "in service" date.

( g)

The month and year to remove from service which shall be no more than 10 years from the date of manufacture.

( h)

Pictogram to indicate the necessity for users to read the instructions for use. ( See Figure 5.1.)

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AS/NZS 1891.1:2020

•

I Figure 5.1 - Pictogram - Read instructions before using Labelling of any component associated with an integral pole strap or lanyard shall conform to the labelling requirements of AS 1891.5. 5.2.2 Attachment points Attachment points on harnesses shall be identified by either labelling each attachment point or by provision of included information permanently attached to the harness. Attachment point identification shall use the usage designation as listed in Table 5.1. Table 5.1 - Attachment point usage designation Attachment point position/Type

Usage designation

Centre-line front or dorsal

Fall-arrest

Centre-line rear waist

Restraint

Centre-line front - Lower body harness Limited fall-arrest Side-waist Restrained fall-arrest, or strap attachment pole (Pole strap attachment) Shoulder (Retrieval) 5.2.3

Retrieval point

Comments

Attachment points on combination harnesses are only suitable for fallarrest when both upper and lower body components are fitted Not to be used for fall-arrest or limited fall-arrest Not to be used for fall-arrest Not to be used for free fall-arrest or limited free fall-arrest. Only to be used as a pair Only to be used as a pair for retrieval

Readability

Labelling shall be legible and readable, enabling the user to clearly distinguish individual letters or characters from each other. The labelling shall be designed to be clearly legible throughout the life of the product under normal usage conditions .

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AS 1891.2—2001 AS/NZS 1891.2

Australian/New Zealand Standard™ Industrial fall-arrest systems and devices Part 2: Horizontal lifeline and rail systems

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AS 1891.2—2001 1.4 SYSTEM ACCEPTANCE CRITERIA Criteria are set for the acceptance of horizontal lifeline and rail systems at three levels as follows: (a)

Proprietary systems Systems for which the fall-arrest performance of any selected layout design can be determined by a method or program which has been verified by means of performance testing of prototypes over an adequately representative range of layout configurations. NOTE: It should not be implied from the above description that the Standard requires any details of commercially sensitive technology to be revealed.

(b)

Prescribed configuration systems Systems set up in accordance with configurations prescribed in AS/NZS 1891.2, Supplement 1 are deemed to comply with this Standard.

(c)

Rigid systems Horizontal life rail systems whose performance can be reliably predicted by design calculation.

Detailed requirements for meeting these criteria are set out in Section 4.

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1.5 RESTRAINT SYSTEMS A restraint system not capable of sustaining fall-arrest loadings shall be clearly and permanently marked ‘Suitable for restraint only. Not to be used for fall-arrest.’ NOTE: A restraint system using a horizontal line or rail, provided and located such that it effectively prevents users reaching a point at which a free fall could occur, need not meet this Standard. However, if foreseeable misuse of the restraint system could result in a free fall, it is advisable to provide a horizontal lifeline or rail as specified in this Standard.

1.6 LOADING OF LINES IN SERVICE Flexible line systems shall not be subjected to any operator loading in normal service other than substantially horizontal restraint forces, i.e. they shall not be used for work positioning purposes, unless specifically designed and certified for such use. NOTE: A primary reason for this requirement is to prevent creep in any part of the system, such as energy absorbers, which might, over time, alter its fall-arrest performance characteristics.

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AS 1891.2—2001 2.5 LINE ANCHORAGES 2.5.1

End anchorage hardware

End anchorage hardware, i.e. fixing posts, bearing plates, bolts and other anchorage fittings, shall be designed to resist and to transfer to the structural anchorage, minimum breaking forces as follows: (a)

A force along the axis of the line at the anchorage, of at least twice the maximum fallarrest force in the line either specified or calculated for the particular configuration in which the line is to be used, see Figure 2.1(a). NOTE: This is the axial force which results from a fall-arrest loading acting at right angles to the axis of the line.

(b)

A force of 12 kN acting at right angles to the axis of the line and in the direction of loading if there were a fall close to the anchorage, see Figure 2.1(b).

The forces specified in Items (a) and (b) shall be considered as acting independently from one another. 2.5.2

Intermediate anchorage hardware

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Intermediate anchorage hardware shall be designed to resist and to transfer to the structural anchorage minimum breaking forces as follows: (a)

A force of 12 kN acting at right angles to the axis of the line and in the direction of fallarrest, i.e. in the direction of loading if there was a fall close to the anchorage, see Figure 2.1(c).

(b)

If the line is diverted through an angle greater than 15 degrees, the resultant of the maximum specified or calculated horizontal forces induced in the line on each side of the anchorage by a fall-arrest, multiplied by a factor of safety of two, see Figure 2.1(d).

The forces specified in Items (a) and (b) shall be considered as acting independently of one another. These design forces shall apply to both single and multiple user systems. Rope apertures shall be designed to prevent damage to the rope and to allow it to run freely through the aperture unless the supports for the apertures are designed to distort to absorb the fall-arrest energy and the system performance predictions take the restricted rope movement at the aperture into account. 2.5.3

Drilled-in anchorages

Drilled-in anchorages such as friction and glued-in anchorages shall only be used if they are installed in a position so that the shear load is at least twice the tension load. For an anchorage device inserted at right angles into a surface, this translates to a pull at an angle not exceeding 20 degrees to the surface. 2.6 MOBILE ATTACHMENT DEVICES In locations where a user would be at risk of a fall, mobile attachment devices shall be either permanently fixed to the line or rail, or shall be removable only by two consecutive deliberate manual actions. Purpose designed and built devices shall meet the following requirements: (a)

They shall be fully compatible with the system with which they are to be used.

(b)

Design shall be such that the device cannot appear to be attached to its line or rail without being positively locked on to it.

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AS 1891.2—2001 (c)

Suitable stops shall be fitted to prevent the device running off the ends of the rail or line in locations where there could be risk of a fall.

(d)

When tested in accordance with Appendix A the device shall resist a static force of 15 kN without breaking.

Snap hooks and karabiners used as mobile attachment devices shall meet the requirements for attachment hardware specified in AS/NZS 1891.1. NOTE: So as to resist wear from frequent travelling along the line, snaphooks and karabiners should be selected for both the suitability of the material from which they are made and the thickness of that material. The surface finish on these devices should be such as will not damage the line or fittings.

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Pulleys, where used, shall meet the same requirements as specified above for purpose built devices.

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AS 1891.2—2001

Fall-arrest line

'12

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(a) End anchorage force along axis of line

(b) End anchorage force at right-angles to line

Resultant force (R)

' '12

Fall-arrest line force x 2

(d) Intermediate anchorage force in plane of line (line diverted through angle greater than 15°)

FIGURE 2.1 FORCES ON END AND INTERMEDIATE ANCHORAGES

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AS 1891.2—2001

S E C TIO N

SYST E M PERFO RM A N CE R EQUIR EMENTS

3.1 HORIZONTAL LIFE RAILS Horizontal life rails together with their supports shall be designed and constructed so that they are capable of sustaining a design ultimate force in the direction of fall arrest on each span or each 1.0 m run of rail where spans are less than 1.0 m, as follows: (a)

A base force of 15 kN for one person centrally located on the span or 1.0 m run.

(b)

A further 6 kN for each additional person permitted on the span or 1.0 m run in accordance with the manufacturer or supplier’s directions or recommendations, the additional forces to be equally distributed either side of the centre of the span or 1.0 m run, and equally spaced so as to cover the entire span.

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Existing installations, where access to original design calculations is no longer available and which are not amenable to reliable calculation of strength based on existing conditions, shall be subjected to the static proof load test in Appendix B and shall sustain the specified load without fracture or permanent deformation. 3.2 HORIZONTAL LIFELINE SYSTEMS 3.2.1

Design requirements

The following requirements shall be incorporated into the design of flexible line systems including associated documentation where appropriate: (a)

The system shall not allow the fall-arrest loading exerted on a user’s harness to exceed 6 kN when the user is equipped with and is correctly using, a lanyard assembly as specified in AS/NZS 1891.1. NOTE: This requirement is designed to ensure that no configuration can allow so much fall energy to be developed that the capacity of the personal energy absorber will be exceeded.

(b)

Methods or programs for the prediction or calculation of end anchorage forces and line deflections when arresting a fall shall be based either directly on test results or on interpolation of test results in respect of span lengths, and interpolation or extrapolation in respect of overall line length.

(c)

Calculation of safe clearances below the system at any point shall be based on the maximum deflection of the system at that point when arresting a fall, including the effects of personal and line energy absorber extension, the maximum height of a user, plus a further clearance of at least 1.0 m.

(d)

All hardware shall meet the relevant requirements of Section 2.

3.2.2

Performance requirements

Performance requirements for horizontal lifeline systems are specified as follows: (a)

Dynamic performance tests shall be carried out for the purpose of verifying the performance prediction information provided to users and installers by the system supplier as follows: (i)

Test configuration The tests shall be performed using test configurations selected to be as representative as possible of the range of configurations the manufacturer’s instructions and recommendations allow. NOTE: Guidance on the selection of test configurations is given in Appendix C. These may need to be modified to suit unusual systems or configurations.

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AS 1891.2—2001 (ii)

Test conduct When tested in accordance with Appendix D, both the maximum force developed in the line and the maximum dynamic deflection of the line for each centre-span loading on the test configuration shall not vary from the manufacturer’s prediction by more than ±20%.

A static strength test designed to test the integrity of the system shall be carried out as specified in Appendix E. When tested in accordance with Appendix E, a static force of 12 kN shall not cause release of the load or fracture of any component of the system, designed extension of energy absorbers or designed yield of any component excepted.

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(b)

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AS 1891.2—2001

S EC TION

S Y S T E M A C C E P T A N CE C RIT E RI A

4.1 GENERAL This Section sets out the circumstances under which each category of horizontal life rail or lifeline system can be accepted as complying with this Standard. In each case acceptance shall also be contingent upon individual hardware items conforming to the requirements of Section 2. 4.2 PROPRIETARY SYSTEMS

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A proprietary system may be accepted if it meets either of the following criteria: (a)

Evidence that production samples have met both the design requirements and the verification and integrity test requirements for both dynamic performance and static strength, as specified in Clause 3.2, using an adequately representative schedule of tests.

(b)

The material and installation characteristics of the system lie between two already verified systems and are identical in all other aspects to the characteristics of those systems to the extent that its performance can be validly predicted. NOTE: Although this Clause will normally be applied to commercially marketed systems, it is applicable to any system where a prototype has been fully tested and subsequent systems are to be made and installed to an identical design and to a configuration whose performance can be reliably predicted.

4.3 PRESCRIBED CONFIGURATION SYSTEM A range of prescribed horizontal line configurations which are deemed to comply with the requirements of this Standard is specified in AS/NZS 1891.2 Supplement 1. An installation may be accepted if it conforms with such a configuration and the related requirements set out in the Supplement. 4.4 RIGID SYSTEMS Horizontal life rail systems may be accepted if they meet the requirements specified in Clause 3.1.

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AS 1891.2—2001

S E C TIO N

INS TR UCT IONS

AND

M A RKIN G

5.1 GENERAL For the purpose of providing instructions and marking for horizontal lifelines and rails, systems shall be dealt with under either of the following categories: (a)

Systems supplied in kit form and intended to be installed by the purchaser or user (see Clause 5.2).

(b)

Systems installed by the supplier, under the supplier’s supervision or by an installer authorized by the supplier (see Clause 5.3).

5.2 SYSTEMS SUPPLIED IN KIT FORM 5.2.1

Instructions for use

Clear instructions for the assembly, installation and use of systems, system components and associated hardware items shall be supplied for all equipment supplied in kit form and covered by this Standard. The following matters shall be included in the instructions:

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(a)

For horizontal lifeline systems, the following installation information: (i)

A means of determining the various configurations in which the system may be used.

(ii)

Limits which must be observed when selecting configurations.

(iii)

A means of determining the maximum load which the end anchorage will impose on the structure in the direction of the line in the event of a fall. NOTE: A warning should be included to the effect that the load needs to be multiplied by a safety factor of 2 when determining the design load on the structure (see Clause 2.5.1(a)).

(iv)

The requirement that all end and intermediate anchorages are to be capable of resisting an ultimate load of 12 kN at right angles to the axis of the line and in the direction of loading if there were a fall close to the anchorage.

(v)

A means of determining the fall-arrest clearances required under each span of the system.

(vi)

A means of determining how many people may work within any one span.

(b)

Advice as to which fall-arrest devices, harnesses and lanyard assemblies as specified in AS/NZS 1891.1 or AS/NZS 1891.3 are suitable for connecting users to the system. On systems designed for use as an anchor for an industrial rope access system, advice of this shall also be provided.

(c)

On systems which do not have a mobile attachment device capable of automatically passing an intermediate anchorage, advice that two separate means of attachment to the line, allowing at least one to be attached at all times, should be used.

(d)

Advice that the level of the line in relation to each worker should be high enough to minimize the fall distance consistent with the wearer’s ability to perform tasks.

(e)

A warning that if any part of an assembly is to be exposed to chemicals, e.g. cleaning materials or hazardous atmospheres, the user should consult the manufacturer to determine whether the part is suitable for use in that environment.

(f)

A warning that fibre rope and webbing lines or components should be destroyed or returned to the manufacturer for inspection if a fall has been sustained.

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AS 1891.2—2001 (g)

A warning that after a fall the system should be taken out of service until it has been inspected, repaired if necessary and re-certified as safe by a competent person.

(h)

A warning that if line energy absorbers that absorb energy by permanent deformation or destructive action have begun to activate, the system should not be used until the item is replaced and the system re-certified as safe by a competent person.

(i)

A warning that if a line is configured in such a way that a person falling would deflect the line so much that any second person attached to the same span could be pushed or pulled into a fall, that span must only be used by one person at a time.

(j)

The recommended maintenance interval and a reference to maintenance instructions including any specific service requirements for particular items.

(k)

Advice that only people who have the necessary competence should be allowed to use the system.

5.2.2

Marking

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All purpose designed mechanical devices forming part of a horizontal lifeline system supplied separately or as part of a kit shall be clearly and indelibly marked or permanently labelled by the manufacturer with the following information: (a)

Manufacturer’s name, trade name or, trademark.

(b)

Serial or batch number in the case of—

(c)

(i)

line tensioner;

(ii)

line energy absorber;

(iii)

mobile attachment device; and

(iv)

line anchorages, end and intermediate.

Where a device is designed for use in certain specific configurations, a statement of this, together with any applicable limitations or warnings of possible inadvertent misuse.

NOTE: Manufacturers making a statement of compliance with this Australian/New Zealand Standard on a product, packaging, or promotional material related to that product are advised to ensure that such compliance is capable of being verified.

5.3 INSTALLED SYSTEMS Clear instructions for the use of installed systems including associated hardware supplied as part of the system shall be supplied by the supplier or installer of the system. The following matters shall be included in the instructions: (a)

Advice as to which fall-arrest devices, harnesses and lanyard assemblies, as specified in AS/NZS 1891.1 or AS/NZS 1891.3, are suitable for connecting users to the system. On systems designed for use as an anchor for an industrial rope access system, advice of this shall also be provided.

(b)

(c)

(d)

A warning that fibre rope and webbing lines or components should be destroyed or returned to the manufacturer for inspection if a fall has been sustained.

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AS 1891.2—2001 (e)

A warning that after a fall the system should be taken out of service until it has been inspected, repaired if necessary and re-certified as safe by a competent person.

(f)

A warning that if any line energy absorber that absorbs energy by permanent deformation or destructive action has begun to activate, the system should not be used until the item is replaced and the system re-certified as safe by a competent person.

(g)

The recommended maintenance interval and a reference to maintenance instructions.

(h)

Advice that only people who have the necessary competence should be allowed to use the system.

5.4 SYSTEM INFORMATION PLATES

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A system information plate shall be displayed at each regular entry point to any permanently installed horizontal lifeline or rail system. The plate shall provide the following information: (a)

Manufacturer’s and installer’s name and installation date.

(b)

A unique identification number.

(c)

An instruction that a personal energy absorber or a fall-arrest device with energy absorbing properties must be used.

(d)

Any special instructions for use, including the number of users allowed on the system or on any one span at once.

(e)

Servicing requirements and instructions, together with inspection and servicing intervals and the dates on which they are to be carried out.

(f)

The month and year by which the system should be taken out of service unless it has been re-certified by a competent person in accordance with manufacturer’s instruction as safe for continued use. This date shall be not more than 10 years from the date of original installation nor more than 5 years from any subsequent re-certification.

The plate shall be made from tamper resistant material and installed so as to retain the information in legible condition for the expected life of the installation.

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AS 1891.2 Supplement 1—2001 AS/NZS 1891.2 Supp1

Australian/New Zealand Standard™ Industrial fall-arrest systems and devices Part 2: Horizontal lifeline and rail systems Supplement 1: Prescribed configurations for horizontal lifelines (Supplement to AS/NZS 1891.2:2001)

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AS 1891.2 Supplement 1—2001 STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND Australian/New Zealand Standard Industrial fall-arrest systems and devices Part 2: Horizontal lifeline and rail systems Supplement 1: Prescribed configurations for horizontal lifelines (Supplement to AS/NZS 1891.2:2001) 1 SCOPE This Supplement prescribes a range of system configurations which have been determined by investigation to meet the performance and safety requirements of AS/NZS 1891.2. It also specifies hardware and installation requirements for such systems.

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2 GENERAL A horizontal lifeline system whose configuration and installation meet the requirements of this Supplement together with all other relevant requirements of AS/NZS 1891.2 shall be deemed to comply with that Standard. NOTES: 1

Installers of horizontal lifelines and rails are advised to check whether they are required to meet any certification requirement in the State in which a system is to be installed.

The prescribed configurations in this Supplement have been derived from a series of full- scale dynamic tests (see Preface), and are designed to provide users with reasonably flexible means of setting up a horizontal lifeline system without recourse to either extensive testing, complex calculation or proprietary systems. Further detail on this testing and derivation can be obtained from the research paper referenced in the Preface.

3 REFERENCED DOCUMENTS The following documents are referred to in this Supplement: AS 1353 1353.1

Flat synthetic-webbing slings Part 1: Product specification

1380 1380.1

Fibre-rope slings Part 1: Product specification

1666 1666.1

Wire-rope slings Part 1: Product specification

2317

Collared eyebolts

2319

Rigging screws and turnbuckles

2741

Shackles

3569

Steel wire ropes

3775

Chain slings—Grade T

4497 4497.1

Roundslings—Synthetic fibre Part 1: Product specification

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AS 1891.2 Supplement 1—2001 AS/NZS 1891 1891.1 1891.2 1891.3 NZS 5227 5227.2

Industrial fall-arrest systems and devices Part 1: Safety belts and harnesses Part 2: Horizontal lifeline and rail systems Part 3: Fall-arrest devices Specification for flat lifting slings Part 2: Flat woven webbing lifting slings made of man-made fibre for general service

4 DEFINITIONS For the purpose of this Supplement the definitions in AS/NZS 1891.1 and AS/NZS 1891.2 apply. 5 GENERAL REQUIREMENTS The components of a typical horizontal lifeline system are illustrated in Figure 1. Use of the prescribed configurations for a horizontal lifeline set out in this Supplement shall be subject to the following:

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(a)

A fall-arrest harness as specified in AS/NZS 1891.1 with— (i)

a lanyard assembly (i.e. including a personal energy absorber) meeting the requirements of AS/NZS 1891.1; or

(ii)

a fall-arrest device meeting the requirements for a Type 2 or 3 device in AS/NZS 1891.3;

shall be worn or used by all users of the system strictly in accordance with manufacturer's instructions for fitting and use. NOTES: 1

The predicted performance of the system assumes that the fall-arrest force in the lanyard will not exceed 6 kN.

Not all Type 2 or 3 fall-arrest devices are suitable for use with horizontal lifelines. Users should check with the manufacturer of the device if in doubt.

(b)

The line shall run freely through intermediate supports.

(c)

Means of passing an intermediate anchorage without complete disconnection from the line shall be used by all users of the system. This is typically achieved by provision of a second lanyard or a dual attachment lanyard similar to that illustrated in Figure 2.

(d)

The maximum overall length of the line shall be 100 m, and of any one span, 10 m. The minimum overall length of the line and of individual spans shall be limited to the minimum configuration allowed in the Tables given in Clause 6.

(e)

The number of persons using the system at any one time shall not exceed four and the number using any one span at any one time shall be limited to either one or two depending on the number for which provision has been made as set out in Clause 6.1(a).

(f)

The line shall be limited to 8, 10 or 12 mm diameter galvanized steel cable of 6 × 24 fibre core construction, Grade 1570 or 1770 in accordance with AS 3569.

NOTE: Use of a cable of a grade different from that specified may result in significantly increased anchorage forces under fall-arrest conditions and is therefore not permitted by this Supplement.

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AS 1891.2 Supplement 1—2001

FIGURE 1 TYPICAL ARRANGEMENT OF A PRESCRIBED CONFIGURATION SYSTEM

NOTE: Care needs to be taken that the energy absorber is not ‘short-circuited’, i.e. by clipping one leg of the dual lanyard back to the harness.

FIGURE 2 DUAL ATTACHMENT LANYARD

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AS 1891.2 Supplement 1—2001 (g) (h)

The horizontal deviation of the line at any intermediate support (see Figure 3), shall not exceed 15 degrees. (See also Clause 6.1(c)). Line energy absorbers shall not be used.

NOTE: Predicted maximum system deflections under fall-arrest conditions are based on the assumption that line energy absorbers are not used.

(i)

The line shall be rigged so that it is at least 1.5 m above the working platform but preferably above the head height of the people attached to it, and located laterally so that, in the event of a fall, the fall-arrest force cannot act on the cable at an angle greater than 30 degrees to the vertical, measured at right angles to the line as shown in Figure 4.

(j)

The line shall be located so that in the event of a fall remote from the centre of a span, the resulting longitudinal movement or swing during the fall will not bring the user into contact with an obstruction. This should be especially checked in the case of long spans.

(k)

Attachment of lanyards or fall-arrest devices to the line shall be by means of snaphooks, karabiners or pulleys only. Snap hooks and karabiners shall meet the requirements for attachment hardware specified in AS/NZS 1891.1.

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NOTE: So as to resist wear from frequent travelling along the line, snaphooks and karabiners should be selected for both the suitability of the material from which they are made and the thickness of that material. The surface finish on these devices should be such as will not damage the line or fittings.

Pulleys, where used, shall meet the requirements specified in AS/NZS 1891.2 for purpose built mobile attachment devices.

(l)

Lanyard lengths shall be selected so as to limit as far as practicable, any free fall to not more than 2 m.

FIGURE 3 DIRECTION CHANGE AT AN INTERMEDIATE ANCHORAGE

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AS 1891.2 Supplement 1—2001

NOTE: Care is needed that the lanyard cannot be damaged in a fall of the type depicted in the illustration. Where practicable, the lanyard should be short enough to prevent a person falling off the working platform. FIGURE 4 ANGULAR LIMIT ON DIRECTION OF LINE LOADING

6 SYSTEM DESIGN PARAMETERS 6.1 Anchorage forces Design force to be used in the design or strength assessment of anchorages shall be as follows: (a)

End anchorages The end anchorages shall be designed to resist without breaking, the forces shown in Figure 5. These are as follows: (i)

Force F1, the horizontal design ultimate force obtained from Tables 1, 2 or 3 for either one person or two people maximum on any one span. This force acts generally horizontally in the line of the cable.

(ii)

Force F2, a design ultimate force of 12 kN acting in the direction of fall-arrest loading which may be vertical or at an angle to the vertical of up to 30 degrees as shown in Figure 5.

These forces shall be considered as two separate load cases for design purposes. NOTES: 1

The figures in the Tables are predicted actual values multiplied by a safety factor of 2.0 and are the minimum breaking forces for which end anchorages and anchorage fittings are intended to be selected and installed.

The design should not be limited to one person only, unless it can be guaranteed that only one person will ever be present on any one span at a time.

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AS 1891.2 Supplement 1—2001 (b)

Intermediate anchorages The force to be used in the design or strength assessment of intermediate anchorages meeting the relevant requirements of Clause 5 shall be a minimum breaking force of 12 kN in the direction of fall-arrest loading, which may not necessarily be vertically downwards (see Figure 5). This force shall apply to use of the span by either one or two persons.

(c)

Line deviations If the horizontal deviation at a potential intermediate anchorage position is greater than 15 degrees the line shall be terminated and restarted at that point. Either two separate anchorages each meeting the strength requirement for an end anchorage for its respective part of the divided line, or a single anchorage capable of independently meeting each end anchorage load and able to physically accommodate both line terminations shall be provided.

TABLE 1

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DESIGN ULTIMATE END ANCHORAGE FORCES IN PRESCRIBED CONFIGURATION HORIZONTAL LIFELINES USING 8 mm GRADE 1570 OR 1770 CABLE, 6 × 24 FIBRE CORE, MIN. BREAKING STRENGTH 28.2 kN Design ultimate end anchorage force, kN Length of longest single span, m Overall line length m

Up to 4.0

4.1 to 6.0

6.1 to 8.0

8.1 to 10.0

One person per span

Two persons per span

One person per span

Two persons per span

One person per span

Two persons per span

One person per span

Two persons per span

4.0 to 6.0

—

6.01 to 8.0

—

8.01 to 10.0

10.01 to 15.0

15.01 to 20.0

26.4

20.01 to 25.0

24.7

27.9

25.01 to 30.0

23.2

26.3

30.01 to 35.0

22.0

25.1

27.5

35.01 to 40.0

21.2

24.0

26.4

28.2

40.01 to 45.0

20.4

21.3

25.5

27.2

45.01 to 100.0

19.9

22.3

24.4

26.3

* Cable strength is exceeded in these cases. A larger diameter cable will be required. NOTE: The end anchorage forces in the Table will only apply if the exact specified size and grade of cable is used. If a stronger or thicker cable is used it may be stiffer and the end anchorage forces could therefore be significantly increased.

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AS 1891.2 Supplement 1—2001 TABLE 2 DESIGN ULTIMATE END ANCHORAGE FORCES IN PRESCRIBED CONFIGURATION HORIZONTAL LIFELINES USING 10 mm GRADE 1570 OR 1770 CABLE, 6 × 24 FIBRE CORE, MIN. BREAKING STRENGTH 44 kN Design ultimate end anchorage force, kN Length of longest single span, m

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Overall line length m

Up to 4.0

4.1 to 6.0

6.1 to 8.0

8.1 to 10.0

One person per span

Two persons per span

One person per span

Two persons per span

One person per span

Two persons per span

One person per span

Two persons per span

4.0 to 6.0

44.0

—

6.01 to 8.0

40.3

—

8.01 to 10.0

37.5

42.7

10.01 to 15.0

32.7

37.5

41.1

44.0

15.01 to 20.0

29.9

34.0

37.5

40.0

20.01 to 25.0

27.9

41.7

31.7

34.7

37.2

25.01 to 30.0

26.3

39.3

29.9

32.7

35.2

30.01 to 35.0

25.1

37.5

28.4

42.7

31.1

33.2

35.01 to 40.0

23.9

35.7

27.2

40.8

29.9

32.0

40.01 to 45.0

23.1

34.5

26.3

39.3

28.7

42.9

30.8

45.01 to 100.0

22.3

33.3

25.2

37.9

27.6

41.5

29.9

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AS 1891.2 Supplement 1—2001 TABLE 3 DESIGN ULTIMATE END ANCHORAGE FORCES IN PRESCRIBED CONFIGURATION HORIZONTAL LIFELINES USING 12 mm GRADE 1570 OR 1770 CABLE, 6 × 24 FIBRE CORE, MIN. BREAKING STRENGTH 63.3 kN Design ultimate end anchorage force, kN Length of longest single span, m

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Overall line length m

Up to 4.0

4.1 to 6.0

6.1 to 8.0

8.1 to 10.0

One person per span

Two persons per span

One person per span

Two persons per span

One person per span

Two persons per span

One person per span

Two persons per span

4.0 to 6.0

47.9

54.7

—

6.01 to 8.0

43.6

49.6

54.4

—

8.01 to 10.0

40.4

60.7

46.0

50.8

54.7

10.01 to 15.0

35.5

53.1

40.4

60.7

44.3

47.6

15.01 to 20.0

32.3

48.3

36.7

54.9

40.4

60.7

43.5

20.01 to 25.0

30.0

45.1

34.0

50.9

37.5

56.1

40.4

60.7

25.01 to 30.0

28.3

42.3

32.3

48.3

35.2

52.8

38.0

57.1

30.01 to 35.0

27.1

40.5

30.7

45.9

33.6

50.4

36.0

54.0

35.01 to 40.0

25.9

38.7

29.5

44.1

32.3

48.3

34.7

51.9

40.01 to 45.0

24.8

37.2

28.3

42.3

31.1

46.5

33.1

49.5

45.01 to 100.0

24.0

36.0

27.5

41.1

30.0

45.1

32.3

48.3

* Cable strength is exceeded in these cases. NOTE: The end anchorage forces in the Table will only apply if the exact specified size and grade of cable is used. If a stronger or thicker cable is used it may be stiffer and the end anchorage forces could therefore be significantly increased.

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AS 1891.2 Supplement 1—2001 6.2 Fall clearances The vertical clearances required below the level of the cable anchorages to ensure that a falling person does not strike an object prior to fall-arrest, are given in Table 4 for the range of permitted line configurations. The components making up the fall clearances required are illustrated in Figure 6. The fall clearance given in Table 4 may be reduced if either of the following apply: (a)

If a shorter lanyard than the 2.0 m length shown in Figure 6 is used, the difference in length may be subtracted.

(b)

If a fall-arrest device, Type 2 or 3 is used, the resulting shorter free fall may be taken into account.

(c)

If a lesser lanyard assembly extension than that shown in Figure 6 can either be justified from the manufacturer's information or determined from dynamic test, the difference may be subtracted.

TABLE 4

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FALL CLEARANCES REQUIRED FOR PRESCRIBED CONFIGURATION HORIZONTAL LIFELINES Configuration (see Note 1) Overall line length, m

Up to 10.0

10.01 to 30.0

30.01 to 100

Length of longest span, m

Clearance required, m (see Note 2)

4.0 to 6.0

6.5

6.01 to 8.0

6.6

8.01 to 10.0

6.7

4.0 to 6.0

6.9

6.01 to 8.0

6.9

8.01 to 10.0

7.1

4.0 to 6.0

7.1

6.01 to 8.0

7.3

8.01 to 10.0

7.3

NOTES: 1

Some of these configurations are not available for situations where more than one person is connected to a span (see Table 1, 2 and 3).

Derivation of these clearances is illustrated in Figure 6.

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AS 1891.2 Supplement 1—2001 (b)

The following items, where used, shall meet the relevant requirements of the Standards indicated: (i)

Harnesses and lanyard assemblies—AS/NZS 1891.1.

(ii)

Attachment hardware—AS/NZS 1891.1.

(iii)

Fall-arrest devices, Types 2 or 3—AS/NZS 1891.3.

The above items are illustrated on the arrangement diagram in Figure 1. 7.2 End anchorage hardware End anchorage hardware, i.e. shackles and eyebolts, shall meet the working load limit (WLL) specified in Table 5 for the corresponding size and breaking strength of the cable used for the line. Where brackets or fittings other than the above or eyebolts not conforming to AS 2317 are to be used, they shall have a design minimum breaking force in the direction of loading at least equal to that of the cable used for the line. Typical end anchorages and fittings are illustrated in Figure 7. The items in Table 5 shall meet the requirements of relevant Standards indicated in the Table. TABLE 5

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END ANCHORAGE HARDWARE—WLL REQUIREMENTS Cable diameter

Cable min. breaking force kN

Working load limit, t Turnbuckles to AS 2319 WLL

Min. size & grade

Shackles to AS 2741 WLL

L-16 mm 8.0

10.0

28.2

44.0

0.6

1.0

P-10 mm

Min. size & grade

0.75

M-13 mm S-8 mm

L-20 mm

L-16 mm

S-10 mm

Eyebolt in tension

Eyebolt in shear

WLL

Min. size

WLL

Min. size

0.8

M16

2.0

M22

0.8

M16

4.0

M30

1.6

M20

5.0

M33

L-13 mm

S-10 mm P-12 mm

Eyebolts to AS 2317

1.0

M-13 mm S-10 mm T-13 mm

L-20 mm 12.0

63.3

1.0

P-12 mm S-12 mm

L-19 mm 1.5

M-16 mm S-11 mm T-13 mm

7.3 Tensioning hardware If a tensioner is to remain in the line it shall either be a turnbuckle or a rigging screw (see Figure 7) complying with the strength requirements of Table 5. Means of locking off the device shall be provided. Open hooks shall not be used. 7.4 Line terminations The line terminations shall be secured with wedge sockets, double saddle wire rope clips and thimbles, or machine spliced with thimbles as shown in Figure 8. The Figure also shows an unsatisfactory means of attachment in each case. These are not acceptable and shall be avoided. COPYRIGHT Bullivants | Page 183 of 692

AS 1891.2 Supplement 1—2001 7.5 Sling anchorages Where it is desired to use a sling as an anchorage for a horizontal lifeline, the following requirements shall be met: (a)

If the installation is to be permanent, i.e. if it will be in position and available for use for 6 months or longer, the sling shall be galvanized steel wire rope or galvanized chain.

(b)

Subject to Item (a), slings shall comply with one of the following Standards:

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(c)

(d)

(i)

AS 1353.1 for man-made fibre webbing slings.

(ii)

AS 1380.1 for man-made fibre rope slings.

(iii)

AS 1666.1 for wire rope slings.

(iv)

AS 3775 for chain slings.

(v)

AS 4497.1 for roundslings.

(vi)

NZS 5227.2 for flat man-made fibre webbing slings.

The sling shall be selected so that after any derating due to the manner of rigging is taken into account, the breaking strength of the sling is— (i)

twice the maximum fall-arrest force in the line for a steel wire rope sling; or

(ii)

four times the maximum fall-arrest force in the line for fibre rope or webbing slings.

Slings shall be installed with all slack removed. If installed with a basket hitch the angle between the legs of sling shall be 120 degrees maximum. If installed with a choked hitch, the tail shall be kept as short as possible.

NOTE: Failure to observe these requirements may result in greater than expected deflections in the line during a fall-arrest.

Wherever practicable, slings should be rigged with a double wrap. 7.6 Intermediate anchorage hardware Intermediate anchorage hardware shall comprise either a shackle or eyebolt, or a similar fabricated device or bracket having the ultimate strength as specified in Table 6. The minimum aperture size shall be the diameter of the cable plus a minimum clearance of 2 mm. The internal profile of the device which is in contact with the cable shall be smooth with no part of radius less than 5 mm. Any opening device shall be capable of being positively locked. TABLE 6 INTERMEDIATE ANCHORAGE COMPONENTS— SIZE SELECTION Component

Minimum size

Minimum breaking force, kN

in shear

M20

18.2

(ii) in tension

M12

18.8

10 mm nominal

Grade L—19.6

Collared eyebolts to AS 2317— (i)

Shackles to AS 2741

Grade M—24.5 Grade S—49.0 Brackets

12.0

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AS 1891.2 Supplement 1—2001 8 INSTALLATION 8.1 Structural anchorage point

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Structural anchorage points including all brackets and fittings shall be designed and installed to meet the design ultimate strength specified in the system design parameters set out in Clause 6. They shall meet the following requirements: (a)

Provision of new anchorage points shall be either by engineering design or assessment of a proposed anchorage structure by an engineer or other competent person.

(b)

An installed structural anchorage point shall be certified by an engineer or other competent person and shall be proof tested if that person so requires. Installation and proof testing documentation including the engineer's certificate shall be kept in situ for the duration of the works at a short-term installation and with the building or structure management in the case of long-term installations.

(c)

Drilled-in anchorages such as friction and glued-in anchorages shall only be used if they are installed in accordance with manufacturers' instructions and are in a position so that the shear load is at least twice the tension load. For an anchorage device inserted at right angles into a surface, this translates to a pull at an angle not exceeding 20 degrees to the surface. Following installation the anchorage point shall be proof-loaded in all cases by means of an axially applied pull-out load equal to—

(d)

(i)

at least 50% of the design ultimate end anchorage load as specified in Clause 6.1(a)(i), for an end anchorage; or

(ii)

6 kN in the case of an intermediate anchorage provided in accordance with Clause 6.1(b).

Anchorage points shall be provided with information by an appropriate means designed to provide adequate legibility over the entire period of use, as follows: (i)

For systems likely to be in use for 6 months or longer—a system information plate shall be displayed at each regular entry point to the system. The plate shall provide the following information: (A)

Manufacturer’s and installer’s name and installation date.

(B)

A unique identification number.

(C)

An instruction that a personal energy absorber or a fall-arrest device with energy absorbing properties must be used.

(D)

Any special instructions for use, including the number of users allowed on the system or on any one span at once.

(E)

Servicing requirements and instructions, together with inspection and servicing intervals and the dates on which they are to be carried out.

(F)

The plate shall be made from tamper resistant material and installed so as to retain the information in legible condition for the expected life of the installation.

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AS 1891.2 Supplement 1—2001 (ii)

For a shorter term use—the same information required in Item (i) shall be provided but such provision may be by a less permanent means than a plate, e.g. a paper or cardboard notice in a plastic sleeve secured to a point near the anchorage. The time periods in Item (i)(F) shall be shortened to a period not exceeding 6 months.

8.2 Line attachment Typical methods of line attachment are illustrated in Figure 7. Brackets, shackles or other devices used as intermediate anchorage points which have freedom to move, shall be installed so that they cannot jam the cable or jam themselves in their mounting such that unacceptable forces can be imposed on them. Correct and incorrect usage of shackles is illustrated in Figure 9. The aperture in intermediate anchorages shall be as nearly as practicable at right angles to the direction of the line in both the vertical and horizontal planes.

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All shackles, turnbuckles, rigging screws, latched hooks or other openable devices shall be positively locked, latched or moused as appropriate.

FIGURE 9 USE OF SHACKLES AS INTERMEDIATE SUPPORT HARDWARE

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AS 1891.2 Supplement 1—2001 8.3 Line pre-tension A pre-tension of 0.5 to 1.0 kN is required in the line to ensure that deflections under fall- arrest conditions will not exceed values on which the clearances given in Clause 6.2 are based. To ensure that a satisfactory line tension is achieved, the cable shall be tensioned until the sag measured at the centre of each span is within the relevant range of values given in Table 7. Figure 10 illustrates how the sag is measured. The following shall be taken into account when carrying out this tensioning and measuring process: (a)

The line shall be inspected after tensioning and prior to measurement of sag to ensure that all spans have evenly distributed sag.

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NOTES: 1

A shake of the line will usually ensure even distribution among the spans.

The cable may need to be tensioned from both ends, generally if the length exceeds 30 m or it has a number of horizontal deviations.

(b)

Sag shall be measured without any hardware such as attachment hardware attached to the line.

(c)

The values given as the lower and upper ends of the ranges of sag in Table 7 correspond to line tensions of 1.0 kN and 0.5 kN respectively. The preferred sag is nearer the higher end of the range. On no account shall the line be tensioned to a sag less than the lower value as this may lead to excessively high end anchorage forces in the event of a fallarrest.

(d)

The sag values for span lengths other than those tabulated shall be determined by linear interpolation.

TABLE 7 LINE SAG LIMITS TO ACHIEVE PRE-TENSION IN THE LINE OF BETWEEN 0.5 AND 1.0 kN Cable diameter

Intermediate or end span length

Range of sag

4.0

2-6

6.0

7-16

8.0

15-31

10.0

33-47

4.0

5-10

6.0

12-26

8.0

24-49

10.0

37-75

4.0

7-16

6.0

19-37

8.0

35-68

10.0

55-110

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AS 1891.2 Supplement 1—2001

FIGURE 10 A METHOD OF MEASURING LINE SAG

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9 INSPECTION AND MAINTENANCE 9.1 General Inspection and maintenance of systems installed in accordance with this Supplement shall be carried out at two levels, as follows: (a)

Routine inspection at prescribed intervals and correction of faults where detected.

(b)

Inspection after a fall or other event likely to have stressed the system.

Inspection shall be carried out by a competent person. 9.2 Routine inspection Routine inspection of the horizontal lifeline, and end and intermediate anchorages and fittings shall take place at intervals of 12 months or before each use of the system, whichever is the longer period. Items to be checked at each inspection are specified in Table 8. Items which are defective or show wear and which in the opinion of a competent person will render the items unserviceable, shall be discarded. Where fibre rope or webbing slings are used as end anchorages, they shall be inspected at intervals not exceeding 3 months. If installed in an adverse environment an appropriate lesser inspection period shall be observed, taking into account situations where the sling is especially susceptible to mechanical, chemical or heat damage. 9.3 Inspection after fall or other event After the system has sustained either a fall or any other event such as a heavy mass falling onto the line which could stress the system beyond its elastic limit, the following procedure shall take place: (a)

The line shall be immediately withdrawn from use pending inspection for damage.

(b)

The cable shall be inspected over its entire length for damage to or breakage of strands, with particular attention paid to the region of the fall where hardware was connected to the line by each user involved in the fall and at all intermediate anchorages where the line ran through the anchorages when the fall occurred.

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AS 1891.2 Supplement 1—2001 (c)

All hardware, i.e.— (i)

end anchorages, including cable terminations;

(ii)

intermediate anchorages, especially those adjacent to the fall zone;

(iii)

user attachment hardware provided for common use; and

(iv)

personal user hardware, such as harnesses and lanyard assemblies;

shall be checked for mechanical damage and signs of permanent deformation of fittings. Loss of tension in the cable together with locking arrangements for tensioning devices shall also be checked. Items which are defective or show damage and which in the opinion of a competent person will render the items unserviceable, shall be discarded. NOTE: Any stressing of a line will reduce the energy absorbing properties (i.e. increase the stiffness) of the line. A number of falls may lead to the end anchorage forces at fall-arrest becoming significantly higher than those designed for. In such cases, expert opinion should be sought before continuing to use the line.

9.4 Proof testing of drilled-in anchorages

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In addition to the relevant requirements of Clauses 9.2 and 9.3, drilled-in anchorages shall be proof-tested as specified in Clause 8.1(c) as follows: (a)

Routinely at intervals recommended by the manufacturer or every five years, whichever is the shorter interval.

(b)

After the system has sustained a fall-arrest or similar loading from another cause.

TABLE 8 HORIZONTAL LIFELINE AND ANCHORAGE INSPECTION CHECK LIST Component ROPE

Condition or fault to be checked Local deformation, especially adjacent to anchorages and points of attachment of personal fall-arrest hardware Corrosion Broken strands Line tension (sag)

ANCHORAGES—End and intermediate Substrate

Cracking, spalling, corrosion, deformation, looseness

Hardware

Cracking, distortion, looseness, excess wear, corrosion

LINE TERMINALS Splices

Corrosion, cracking, slippage, distortion, looseness Corrosion,

Turnbuckles and tensioners

cracking, distortion, looseness, locking mechanism

Shackles and other rigging fittings

Corrosion, cracking, distortion, looseness, locking mechanism, thread condition

MOBILE ATTACHMENT DEVICES

Wear, corrosion, cracking, distortion, looseness, sharp edges, free movement, correct function, locking mechanism.

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AS/NZS 1891.3:2020

Australian/New Zealand Standard ™ Personal equipment for work at height Part 3: Manufacturing requirements for fall-arrest devices

Originated as AS 1891.3-1992. Jointly revised and designated AS/NZS 1891.3:1997. Second edition 2020.

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AS/NZS 1891.3:2020

Table 1 - Acceptance of systems conforming to international standards Description

Primary function

Secondary function

Typet Guided fall arrest system and rope adjustment devices EN353.1 EN353.2 EN 12841a ANSI/ASSP Z359.15 ANSI/ASSP Z359.16 N/A

Type2 Self-retracting lifelines

Type3 Self-retracting lifelines with retrieval

Type4 Self-retracting lifelines with self-rescue

EN360 ANSI/ASSP Z359.14

N/A

EN 1496 ANSI/ASSP Z359.14c ANSI/ASSP Z359.4d

EN341b ANSI/ASSP z359_4e

a EN 12841 -Type 1 devices shall be Type A only

b EN341 -Type 4 devices shall be Type 1 only c ANSI/ASSP Z359.14 -Type3 devices shall be SRL-R (self-retracting lifeline retrieval) only d ANSI/ASSP Z359.4 -Type3 devices shall be personnel hoist only e ANSI/ASSP Z359.4 -Type 4 devices shall be descent devices only NOTEl

See AS/NZ S 1891.4 for designations of Type 1, Type 2 and Type3 devices.

NOTE 2

A Type 4 device is a Type 2 with a self-rescue feature.

NOTE3 References to ANSI/ASSP and EN standards are undated to indicate that the current edition, including any amendments, is required.

AS/NZS 1891.4:2009 AS/NZS 1891.4:2009

Australian/New Zealand Standard™ Industrial fall-arrest systems and devices Part 4: Selection, use and maintenance

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AS/NZS 1891.4:2009

PREFACE This Standard was prepared by the Joint Standards Australia/Standards New Zealand Committee SF-015, Industrial Height Safety Equipment (formerly Industrial Safety Belts and Harnesses), to supersede AS/NZS 1891.4:2000. It is one of five Standards in the series Industrial fall-arrest systems and devices. The series comprises the following Standards: AS/NZS 1891 1891.1 1891.2 1891.2 Supp1 1891.3 1891.4

Industrial fall-arrest systems and devices Part 1: Harness and ancillary equipment Part 2: Horizontal lifeline and rail systems Supplement 1: Horizontal lifeline and rail configurations for horizontal lifelines Part 3: Fall-arrest devices Part 4: Selection, use and maintenance (this Standard)

systems—Prescribed

This edition has been prepared with the specific intention of aligning it with the recently published edition of AS/NZS 1891.1.

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Principal changes from the previous edition are as follows: (a)

Removal of ‘total restraint’ from the scope of the Standard as equipment provided solely for restraint purposes is not dealt with in the AS/NZS 1891 series of Standards. This Standard recognizes only ‘restraint technique’ which allows for the possibility of a fall and requires the use of fall-arrest rated equipment and anchorages. For clarification purposes a description of ‘total restraint’ is given in Appendix F.

(b)

Minimum allowable anchorage strength to be 12 kN or 15 kN depending on fall distance.

(c)

New terminology for harnesses (full or lower body) and positioning of fall-arrest attachment points.

(d)

Inclusion of twin-tail lanyards.

(e)

In-service values for the extension of personal energy absorbers in fall situations.

(f)

Lower body harness use restricted to limited free fall and restrained fall.

(g)

Updated requirements for operator training and assessment.

(h)

The term ‘suspension trauma’ has been changed to ‘suspension intolerance (trauma)’.

(i)

A belt or waist strap alone in lieu of a harness is no longer permitted for any of the applications in this Standard to protect against a potential fall.

The term ‘informative’ has been used in this Standard to define the application of the appendix to which it applies. An ‘informative’ appendix is only for information and guidance. Statements expressed in mandatory terms in footnotes to figures are deemed to be requirements of this Standard.

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AS/NZS 1891.4:2009

SEC TION

ANC HOR AGES

NOTE: This Section should be read in conjunction with the relevant general requirements and recommendations relating to all systems and equipment given in Section 2.

3.1 ANCHORAGE SELECTION 3.1.1 General Selection of the type and location of anchorages will depend on the nature and location of the task and the type of construction of the building or supporting structure. A summary of types of anchorage, their strength requirements and their application is given in Table 3.1. NOTE: Certain structures may not be capable of providing anchorages of adequate strength for fallarrest purposes as required by this Standard. In such cases alternative methods of protecting workers working at heights, based on appropriate risk assessment, will need to be developed.

TABLE 3.1 STRENGTH REQUIREMENT FOR ANCHORAGES

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kilonewtons Purpose of anchorage (a)

Single point anchorages Free fall-arrest—one person

Free fall-arrest—two persons attached to same anchor

Limited free fall-arrest (including rope access anchorages)

Restraint technique (b)

Ultimate strength in direction of loading (minimum) (see Notes 1 and 4)

12 or 15 (see Note 3)

Horizontal lifelines End anchorages

See Clause 6.2.4

Intermediate anchorages —diversion less than 15°

—diversion 15° or more

12+ (see Note 2)

NOTES: 1

As far as practicable all single point one-person anchorages should meet the 15 kN requirement regardless of primary purpose.

Horizontal component of forces induced during a fall-arrest (multiplied by a safety factor of 2.0) is to added as indicated in Clause 6.2.5.

Anchorage strengths applicable when using a restraint technique, see Clause 2.2.5, are either 15 kN or kN depending on whether the ultimate fall risk is free fall or limited free fall.

‘Ultimate strength’ means that the anchorage may yield at the stated load but must not fail.

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AS/NZS 1891.4:2009 3.1.2 Single point anchorages suitable for direct connection of personal fall-arrest equipment In addition to any specific requirements of the manufacturer of the anchorage system or other related equipment, the following requirements and recommendations for the selection and location of anchorages apply: (a)

The anchorage and the structure to which it is attached shall be capable of sustaining an ultimate load equal to that shown in Table 3.1 for the corresponding anchorage purpose for single person use when loaded in the direction of the lanyard, anchorage line, or restraint line during a fall arrest. This load requirement shall be increased by 6 kN (i.e. to 21 kN) if two people are to use the one point. The maximum number of people connected to any one point shall be two.

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As far as practicable, all single-point anchorages for single-person attachment should have an ultimate strength of 15 kN even though Table 3.1 specifies a lesser strength for some categories. The building or structure and anchorage points shall be assessed by an engineer, unless it is clear to a height safety supervisor that the anchorage system is structurally adequate. An example of where an engineer may not be required is where an anchorage sling of adequate strength is secured around a solid permanent structure such as a plant room. However, if any doubt exists as to the structural adequacy of the anchorage, an engineer shall make the assessment. If called upon to make the assessment the engineer shall certify in writing that all combinations of loads in a worst case situation can be safely contained by the proposed structure and anchorage points. (b)

The following conditions shall apply to the use of anchorages in each of the purpose categories listed in Table 3.1: (i)

Free fall-arrest Required in any situation where a free fall in excess of 600 mm is a possibility.

(ii)

Limited free fall-arrest Limited to any situation where there is no risk of a free fall in excess of 600 mm.

(c)

Signage in accordance with Clause 3.2.5 shall be provided.

(d)

Fall-arrest anchorages shall, except as given below, be located in positions where there is adequate fall distance before the user can strike a lower obstruction, having regard to the fall-arrest equipment likely to be used (see Section 7). Examples include striking any machinery or open window, door or panel during a fall. If it is not possible to provide clearance from all obstructions a person might strike, the requirements of Section 7 shall be observed.

(e)

Lanyards or anchorage lines shall be able to be attached to the anchorages before the operator moves into a position where there would be risk of a fall, unless the operator is already protected by another fall-arrest system.

(f)

Possible deterioration of anchorages or substrate damage, e.g. that caused by chemical attack, corrosion or atmospheric conditions, should be considered in selecting the anchor material and design.

(g)

Where used, drilled-in anchorages such as friction and glued-in anchorages shall be placed so that the shear load is at least twice the tension load. For collared eye-bolts this translates to a pull at an angle not exceeding 20° to the surface in which the bolt is installed.

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AS/NZS 1891.4:2009 Every friction and glued-in anchorage shall be proof loaded to 50% of the design ultimate strength specified in Table 3.1 in accordance with manufacturer’s instructions after installation and prior to its initial use. The proof load shall be applied as an axial pullout force. Proof loading to 50% of design load shall also be carried out as part of subsequent periodic inspections. 3.1.3 Anchorages requiring use of a sling Requirements and recommendations for the selection and location of anchorages are as follows: (a)

All relevant requirements and recommendations in Clause 3.1.2 are applicable.

(b)

The sling shall be of sufficient length so that it can be rigged with the angle between the legs no greater than 120° (see Clause 3.2.4(b)) unless allowance has been made for the higher loads in the legs of the sling which would be imposed by a greater angle.

3.1.4 Horizontal lifelines and rails These forms of anchorage are used where the user needs to be able to move laterally over significant distance whilst connected to the system. Requirements for anchorages for flexible lines and for horizontal rails are covered in Section 6. 3.1.5 Components, used in anchorage systems

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A non-exhaustive list of Standards for components used in anchorage systems is given for information in Appendix B. 3.2 SAFE USE OF ANCHORAGES 3.2.1 General requirements A suitable anchorage point should be as close as practicable to vertically above the place of work to reduce the liability to swing. Where the possibility of swing in the event of a fall is unavoidable, the requirements and recommendations of Clause 3.2.3 should be observed. Adequate fall clearance needs to be provided below the operator. The required clearance shall be calculated as set out in Section 7. Strength requirements for anchorages for use with various fall-arrest systems are specified in Table 3.1. The type of fall-arrest system attached to an anchorage point shall be compatible with the anchorage strength indicated on any sign associated with the anchorage point. A rope or webbing anchorage line should not be placed around a structural member with sharp edges unless suitably protected, e.g. by use of a protective sleeve. 3.2.2 Safe access A safe means of access to an anchorage point in accordance with AS 1657 should be provided. This should take into account the possibility of a fall prior to the operator connecting securely to the anchorage, and after disconnection at the conclusion of the task. Provision shall also be made for the protection of users while transferring between fall arrest systems (see also Clause 6.3(e)). 3.2.3 Avoiding lateral swing—The pendulum effect If there is a lateral offset between the line from the anchorage point to the operator and the line or direction of potential fall, in the event of a fall the operator may suffer hazardous lateral swing. This is commonly known as the pendulum effect. Two common consequences of the pendulum effect are illustrated in Figures 3.1(a) and 3.1(b). The hazard in the first case is a horizontal collision with a fixed object. In the second case it is a greatly extended fall distance. If the length of unsupported line is equal to or more than the height of the edge above the ground, the operator will strike the ground or other obstacle.

AS/NZS 1891.4:2009

SEC TION

INS P E C TIO N , M AINT EN A N CE A N D S T O RAGE

9.1 SUMMARY OF INSPECTION REQUIREMENTS Requirements for the inspection of equipment are summarized in Table 9.1. TABLE 9.1 SUMMARY OF INSPECTION FREQUENCIES

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Items

Reference

Inspection frequency (Note 1)

Personal equipment including harnesses, lanyards, connectors, fall-arrest devices including common use devices

Clause 9.2

Harnesses, lanyards, associated personal equipment

Clause 9.3.2

Fall-arrest devices (external inspection only)

Clause 9.3.4(a)

Ropes and slings

Clause 9.7

Anchorages—drilled-in type or attached to timber frames

Clause 9.3.3

12-monthly inspection by a height safety equipment inspector (see Note 3)

Anchorages—other types

Clause 9.3.3

Frequency of inspection by a height safety equipment inspector as recommended by the manufacturer to a maximum of 5-yearly. 12-monthly inspection in the absence of such recommendations (see Note 3)

Fall-arrest devices—full service

Clause 9.3.4(b)

Frequency of service by a height safety equipment inspector as recommended by the manufacturer to a maximum of 5-yearly. 12-monthly service in the absence of such recommendations (see Note 3)

Horizontal and vertical lifelines— steel rope or rail

Clause 9.3.5

Frequency of inspection by a height safety equipment inspector as recommended by the manufacturer to a maximum of 5-yearly. 12-monthly inspection in the absence of such recommendation (see Note 3)

Horizontal or vertical lifelines —fibre rope —webbing

Clauses 9.3.5 and 9.7

6-monthly inspection by a height safety equipment inspector (see Note 3)

All items of personal and common use equipment

Clause 9.4

Inspection by a height safety equipment inspector on entry or re-entry into service (see Note 3)

All items which have been stressed as a result of a fall.

Clause 9.5

Inspection by a height safety equipment inspector before further use (see Note 3)

Inspection by a height safety operator (see Note 2) before and after each use.

6-monthly inspection by a height safety equipment inspector (see Note 3)

NOTES: 1

Where used in harsh conditions, more frequent inspection may be required.

If the user or operator of the equipment is not competent to carry out this inspection it is to be undertaken by another person who is competent, see Clause 9.2.

All inspections except those by the operator are to be documented (see Clause 9.10).

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AS/NZS 1891.4:2009 9.2 OPERATOR INSPECTION The following items shall be subjected to inspection by the height safety operator of each item before and after each use to ensure that it is in a serviceable condition: (a)

Personal equipment—harnesses, lanyards, connectors, fall-arrest devices.

(b)

Common use equipment—ropes, slings, fall-arrest devices, mobile attachment devices.

Where an operator is not competent to carry out this inspection, e.g. an operator in training, the inspection shall be carried out by an operator who is competent or a height safety supervisor. Inspection shall be by sight and touch. It shall include the opening of any equipment where access for daily inspection is provided, to ensure that internal components are in satisfactory condition. This requirement includes the opening or removal of temporary rope or line protectors, to enable rope to be properly inspected. Operation of the locking mechanism on fall-arrest devices shall also be checked. It should be impressed upon operators that their lives depend upon the continued efficiency and durability of their equipment and that a proper inspection at each time of use is their first line of defence against the hazards of faulty equipment.

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Training and assessment of height safety operators shall include competency in carrying out the operator inspections specified in this Clause. 9.3 REGULAR SCHEDULED PERIODIC INSPECTION 9.3.1 General All items of equipment which are in regular use shall be subjected to periodic inspection and where applicable, servicing, at the manufacturer’s recommended intervals. The intervals given in Table 9.1 for each item, shall apply in the absence of such recommendations. The inspection and servicing shall be carried out by the person specified in Table 9.1. Items used under harsh conditions, e.g. in wet, dusty, abrasive or corrosive environments, shall be inspected more frequently, generally at twice the frequency specified in Table 9.1. NOTE: Product Standards for each of the items dealt with in this Clause place an obligation on manufacturers to provide maintenance instructions and recommended maintenance/inspection/ service intervals.

9.3.2 Harnesses, lanyards and associated equipment Items shall be checked in accordance with manufacturer’s instructions to determine whether there is excessive wear or any other faults liable to render the item unsafe during a fall arrest. NOTE: A recommended check list of items to be inspected is given at Appendix C.

9.3.3 Anchorages Anchorages shall be visually inspected for signs of deterioration which might make them unserviceable, together with any other requirements contained in manufacturers’ instructions. The parent structure shall also be visually inspected for modifications or deterioration which might lead to loss of anchorage strength. Drilled-in anchorages such as friction or glued-in anchorages shall be proof tested in accordance with Clause 3.1.2(g) as part of each inspection.

AS/NZS 1891.4:2009 9.3.4 Fall-arrest devices These are subjected to inspection and servicing in accordance with the following requirements and recommendations: (a)

Inspection In addition to manufacturers’ recommendations, each device shall be externally inspected as specified below. Devices shall be cleaned of any contaminant likely to hinder the correct operation of the device such as dirt, grit, sand, cement, oil and grease. Free movement of all moving parts, firm tension on any springs and correct operation of the locking action shall all be checked. The examination shall include a search for signs of corrosion. Except for servicing as specified in Item (b) where dismantling may be indicated, each of the above operations and checks shall be carried out as far as possible without dismantling the device.

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Flexible anchorage lines used with Type 2/3 fall-arrest devices shall be inspected for wear, cuts, looseness, extension, interstrand wear, corrosion, stiffness, brittleness and condition of terminations. Retracting fibre rope and webbing anchorage lines may, over a period, increase in diameter due to fluffing up of the fibres or, alternatively, they may become swollen following prolonged exposure in wet conditions. This may make the line retract sluggishly. If this occurs, the device shall be taken out of service immediately and quarantined for repair or disposal. NOTE: A further detailed check list of items to be inspected is given at Appendix D.

(b)

Servicing The full service shall include dismantling of the item by a competent person if recommended by the manufacturer. In addition, all of the items in Item (a) above shall be attended to. The check list items in Appendix D are also relevant.

(c)

Service label or tag Each fall-arrest device shall have a service label or tag for recording the last date on which it was fully serviced and shall include the date on which the next service is due.

9.3.5 Horizontal and vertical life lines and rails The inspection shall be carried out in accordance with manufacturer’s instructions. Particular attention shall be paid to the items in the following check list: (a)

Inspection of line anchorage points and rail support anchorages in accordance with Clause 9.3.3.

(b)

Any modification or deterioration of the parent structure which might lead to a loss of anchorage strength.

(c)

Condition and correct operation of line tensioners and line energy absorbers on horizontal life lines.

(d)

Evidence of wear, cuts, looseness, extension, interstrand wear, corrosion, stiffness, brittleness or fraying of steel cables, ropes or webbing used as horizontal flexible life lines or vertical lines used in conjunction with Type 1 fall-arrest devices with special attention given to lines in the vicinity of horizontal life line intermediate anchorages.

(e)

Integrity of cable terminations.

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AS/NZS 1891.4:2009 (f)

Condition of rigid rails to ensure that the rails and all connecting fittings (brackets, plates, clips, nuts, bolts and washers) are intact and properly tightened and free from corrosion, dirt, grit, sand, cement, oil, grease and other contaminants, and that end stops are in good condition.

(g)

Condition of permanently installed mobile attachment devices including travelling them the entire length of the line or rail to verify their correct function.

(h)

Presence of contaminants which could affect operation of the system or individual devices.

9.4 INSPECTION ON ENTRY OR RE-ENTRY INTO SERVICE 9.4.1 Entry into service of a new item Each item shall be inspected as specified in Clause 9.3 before being placed into service, giving particular attention to whether the item has been correctly assembled and whether all component parts are present including instruction manuals where required.

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9.4.2 Re-entry into service after an item has been repaired Each item shall be inspected as specified in Clause 9.3 before being placed into service giving particular attention to whether the item has been correctly repaired and reassembled. This inspection should also give attention to parts of the equipment which were not subject to the repair as these may be due for their periodic inspection independently of the repair taking place. 9.4.3 Re-entry into service after a period of storage or out of service Before use, each item shall be inspected as specified in Clause 9.3 after a period of storage or out of service in excess of the nominated inspection or service interval for that item, or where the item has been stored under conditions suspected of adversely affecting its condition. This requirement also applies to fixed or permanent installations when used less frequently than the maximum inspection interval. 9.5 EQUIPMENT WHICH HAS ARRESTED A FALL OR SHOWS A DEFECT Any piece of equipment including both personal and permanently installed items, which has been used to arrest a fall or which shows any defect during operator or periodic inspection shall be withdrawn from service immediately and a replacement obtained if necessary. A label indicating the condition or defect should be attached to the equipment, and it should be examined by a height safety equipment inspector who will decide whether the equipment is to be destroyed or repaired if necessary and returned to service. In the latter case, details of any repair shall be documented and a copy given to the operator. 9.6 LIFE EXPIRED EQUIPMENT Life expired equipment shall be taken out of service as follows: (a)

Personal equipment—items which have been marked with a date by which they are to be taken out of service in accordance with AS/NZS 1891.1 and that date has been reached, shall be taken out of service and destroyed.

(b)

Horizontal life lines and rails—items which according to their associated system information plate are either to be taken out of service or re-certified by a certain date shall either be dismantled or have recertification that the system is safe for continued use completed before the nominated date (see also Clause 6.3(j)(vi)).

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AS/NZS 1891.4:2009 9.7 INSPECTION OF ROPES AND SLINGS Inspection of the following items should be in accordance with the reference shown: (a)

Working and safety ropes— AS 4142.1.

(b)

Flat synthetic webbing slings—AS 1353.2.

(c)

Wire rope slings—AS 1666.2.

(d)

Synthetic fibre rope slings—AS 4497.2.

9.8 STORAGE AND TRANSPORT Conditions of storage and transport should ensure that no part of the equipment is subjected to unnecessary strain or pressure or to excessive heat, humidity or moisture and that the equipment is protected from contact with sharp edges, corrosive substances and other possible causes of damage. Equipment should be air-dried at ambient temperature before storage. Items made from synthetic materials should be stored away from direct sunlight in a cool, dry place. 9.9 MAINTENANCE

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Equipment shall be maintained in accordance with manufacturer’s instructions. 9.10 EQUIPMENT DATA AND MAINTENANCE RECORDS To ensure the traceability of maintenance records, a record card, history sheet or similar record shall be kept for each of the items of equipment dealt with in this Standard. Documentation on the maintenance and servicing history of an item of equipment shall be freely available to operators and users for at least the life of the item of equipment. The following lists the information to be recorded for each item of equipment where appropriate: (a)

Manufacturer’s, supplier’s or installer’s name and address.

(b)

Manufacturer’s batch number.

(c)

Serial or identifying number.

(d)

Year of manufacture.

(e)

Details of recommended connections to harnesses.

(f)

Type of anchorage line to be used.

(g)

Suitability and limitations on various usages.

(h)

Date of purchase.

(i)

Date first put into service.

(j)

Dates and details of inspections and services.

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AS/NZS 1891.4:2009

APPENDIX A

SUSPENSION INTOLERANCE (TRAUMA) (Informative) Suspension intolerance (trauma), also known as orthostatic intolerance or in medical terms ‘presyncope’, is a natural human reaction to being upright and immobile (e.g. if held in a vertical stretcher, or suspended inanimate in a harness). Blood pools in the legs potentially leading to unconsciousness. If the condition is allowed to develop unchecked, it could be fatal. In clinical trials, although some subjects experienced no effects after prolonged suspension, others experienced fainting or loss of consciousness in just a few minutes. The initial indications are that a person’s susceptibility may be unrelated to fitness level or any other obvious physical condition or attributes.

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Although the condition is still being researched, it is recommended that certain measures be taken to reduce its effects or delay its onset. It appears to help if the person is suspended in a substantially horizontal position or with the knees elevated. Additional seat straps to enable a person to sit, or straps/stirrups designed to enable a person to transfer some of their weight to their legs, are available. These can be used to facilitate raising the knees, adopting a more horizontal position or leg action to maintain return circulation. It is clear however, that an effective incident response plan is necessary to ensure that following an incident, the person can be removed from the suspended position as quickly as possible. NOTE: There are suggestions that once a person is released from suspension, minor changes to standard first aid treatment may assist recovery. The Australian Resuscitation Council has reviewed the matter and has published Guideline 8.25, Harness suspension trauma—First aid management that recommends essentially normal first aid treatment plus the administration of oxygen if available. The Guideline and any revisions is on the Council’s website www.resus.org.au

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AS/NZS 1891.4:2009

APPENDIX C

INSPECTION OF HARNESSES, LANYARDS AND ASSOCIATED EQUIPMENT—CHECK LIST (Informative) This Appendix lists components to be inspected and the conditions or faults to be checked. Component Webbing

Condition or fault to be checked Cuts or tears Abrasion damage especially where there is contact with hardware Excessive stretching Damage due to contact with heat, corrosives, or solvents Deterioration due to rotting, mildew, or ultraviolet exposure Activation of fall indicators where fitted

Snap hooks and karabiners

Distortion of hook or latch Cracks or forging folds

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Wear at swivels and latch pivot pin Open rollers Free movement of the latch over its full travel Broken, weak or misplaced latch springs (compare if possible with a new snap hook) Free from dirt or other obstructions, e.g. rust D-rings

Excessive ‘vertical’ movement of the straight portion of the D-ring where it is retained by the webbing, so that the corners between the straight and curved sections of the D become completely exposed. NOTE: Excessive vertical movement of the ring in its mounting can allow the nose of larger snap hooks to become lodged behind the straight portion of the D, in which position the snap hook can often accidentally ‘roll out’ of the D under load. Cracks, especially at the intersection of the straight and curved portions Distortion or other physical damage of the D-ring Excessive loss of cross-section due to wear

Buckles and adjusters

Distortion of other physical damage Cracks and forging laps where applicable Bent tongues Open rollers

Sewing

Broken, cut or worn threads Damage or weakening of threads due to contact with heat, corrosives, solvents or mildew

Ropes

Cuts Abrasion or fraying Stretching Damage due to contact with heat, corrosives, solvents, etc Deterioration due to ultraviolet light or mildew

Chains

Physical damage Security of attachments to snap hooks, rings, and similar components

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AS/NZS 1891.4:2009

APPENDIX D

INSPECTION OF FALL-ARREST DEVICES—CHECK LIST (Informative) This Appendix lists components of fall-arrest devices to be inspected and particular conditions/faults to be checked. Component Rope or webbing including anchorage lines for Type 2/3 devices

Condition/fault to be checked Cuts Abrasion or fraying Stretching Damage due to contact with heat, corrosive, or solvents Excessive dirt or grease impregnation Anchorage of the anchorage line to the anchorage point (Type 1 devices) Anchorage of the rope end to the drum when the rope is fully extended (Type 2/3 devices)

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Fall-arrest device body

Mounting ring

Physical damage or wear, especially at any pivot points Cracks, especially in corners Mounting security

Body

Physical damage such as significant dents, distortion, corrosion, or cracks Presence of foreign bodies such as small stones within body (to be checked without dismantling) Loose or missing screws, nuts or similar objects (external check only) Position of the clutch compression indicator button (fitted only to rewind drums with steel rope)

Locking mechanism and rope guides

Fall-arrest indicator (if fitted)

Signs of activation

Correct-use labels and service label or tag

Presence and legibility

Excessive wear or ridging on externally visible rope guides Secure locking and holding of rope-locking mechanism when the rope is given a sharp tug Free running of rope through the anchorage with no tendency to stick or bind, and on rewind drum anchorages, complete rewinding of the rope without loss of tension

Hardware

Condition and locking action of any associated snaphooks or links

Fall indicators

Evidence of activation

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AS 1891.5:2020

Personal equipment for work at height Part 5: Manufacturing requirements for lanyard assemblies and pole straps

Originated as part of AS 1891-1976. Previous edition part of AS/NZS 1891.1:2007. Revised in part and redesignated as AS 1891.5:2020.

© Standards Australia Limited 2020 All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher, unless otherwise permitted under the Copyright Act 1968 (Cth).

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AS 1891.5:2020

Section 2

Components

2.1 General This Section specifies design, construction and performance requirements for webbing, rope and chain used as a component of an energy absorber, lanyard assembly or pole strap.

2.2 Webbing and thread 2.2.1

Design and construction

All lanyard assembly/pole strap load bearing components shall be manufactured from high-tenacity synthetic fibre. Where webbing is woven in a shuttleless loom, lock threads shall be incorporated. All threads contained in webbing shall be lock-joined or otherwise secured in the weave. Where the webbing or equivalent material is sewn, it shall be carried out on a lockstitch machine and be securely finished by overstitching and sewing not less than 2 mm from the edge of the webbing. Threads for sewing load bearing components shall be of a contrasting colour to the webbing. NOTE The thread should be manufactured from high tenacity synthetic fibre and have a melting point and chemical resistance equivalent to or superior to the material being sewn.

2.2.2 Performance requirements

Loadbearing webbing shall be tested in accordance with Appendix A for resistance to degradation by either artificial light or daylight. When tested in accordance with Appendix A the minimum breaking strength of the three exposed samples shall be at least 70 % of the mean of the breaking strength of the three unexposed samples. Unexposed samples shall withstand a force of 15kN when subjected to the static test load in accordance with Appendix A.

2.3

Ropes and chains

Ropes and chains used in lanyard assemblies and pole straps shall be in accordance with the following Standards: Syntheticfibre ropes (not Kernmantle type)� AS 4142.2. Syntheticfibre ropes (Kernmantle type)- AS 4142.3, EN 1891. (c)

Steel wire rope - AS 3569.

(d)

Steel chain - AS 2321.

2.4 Hardware 2.4.1

Finish

All terminating, connecting and adjusting hardware shall be free of burrs, fins, irregularities and sharp edges which would affect the function or safe handling during use. 2.4.2 Corrosion, protection, coatings and testing

Metal components, other than those constructed of stainless steel, shall be coated for corrosion protection. All metal components shall be tested in accordance with ISO 9227 neutral salt spray (NSS) © Standards Australia Limited 2020 Bullivants | Page 206 of 692

AS 1891.5:2020

test [24 h testing + 1 h drying + 24 h testing + 1 h drying and examined within 90 s after drying]. Following testing (a )

products with moving parts shall still function as designed; and

( b)

there shall be no loss of the protective coating which exposes underlying base material.

NOTE

Tarnishing and discolouration are acceptable.

2.4.3

Connectors

Connectors shall be in accordance with either ( a)

ANSI/ASSP 2359.12; or

(b)

EN 362.

Connectors conforming with EN 362 shall also have a gate resistance (face and side) .of 6 kN minimum.

 

AS 1891.5:2020

Section 4

Instructions and labelling

4.1 Instructions for use Clear instructions for fitting, adjustment and use shall be supplied with each component covered by this Standard. The following additional matters shall be included in the instructions:



       

(a)

Advice that users may need to consult AS/NZS 1891.4 for requirements on selection, use, maintenance and training.

( b)

Advice on the need to be competent in the use of equipment before beginning any tasks requiring its use.

(c)

The limitations of use of the equipment and warning against making alterations or additions to it not agreed to by the manufacturer.

(d)

Advice to minimize free-fall distance (maximum free-fall 2 rn).

(e)

Advice to make certain any connection to a harness or anchor is checked before use.

CfJ

(g)

A warning that lanyard assemblies are required to be removed from service if a fall has been sustained.

( h)

The manufacturer's inspection and maintenance intervals and a reference to maintenance instructions.

(i)

Instruction that the maximum life of textile components of products covered by this Standard is 10 years from the manufacturing date.

(j)

Advice that user mass is defined as the mass of the user PLUS their clothing, personal protective equipment, and c?rried tools and materials.

(k)

At a minimum, a table of the format shown in Table 4.1 shall be provided, that stipulates the minimum fall clearance required below the anchorage point, for the minimum and maximum user capacity specified for the lanyard. Fall clearance is rounded up to one decimal point.

Table 4.1 sets out the format for the minimum fall clearance. Example data are provided in Table 4.2.

Table 4.1 - Minimum fall clearance required below the anchorage point

Minimum rated capacity Optional mid-range data point Maximum rated capacity

Lanyard user capacity including clothing, tools kg

xx xx xx

Minimum fall clearance required below anchorage point m

E + L+ 2.8 E + L+ 2.8 E + L+ 2.8

Key

E = Energy absorber extension: Final length of test specimen lanyard under load - initial length of test specimen lanyard. L = Length of lanyard to be supplied, measured between bearing points as per Figure 3.5. 2.8 m = Additional fall clearance considerations specified in AS/NZS 1891.4, including: (i) Height of operator (includes D ring slide and harness stretch): 1.8 m; and (ii) Residual clearance: 1 m. NOTE In the calculations above, the lanyard is used in accordance with AS/NZS 1891.4. © Standards Australia Limited 2020 Bullivants | Page 208 of 692



AS 1891.5:2020

EXAMPLE Table 4.2 is provided as an example using a 4 m lanyard. In testing, the energy absorber in the lanyard experienced 0.6 m extension with 60 kg, 1.15 m extension with 100 kg and 1.82 m extension with 160 kg.

Table 4.2 - Example: Minimum fall clearance required below the anchorage point

Minimum rated capacity Optional mid-range data point Maximum rated capacity

 c

  

Minimum fall clearance required below anchorage point m 7.4 8 8.7

The instruction shall advise that additional fall clearance considerations may need to be made for application scenarios that include: (i )

A nchor system deflection.

(ii )

Swing fall clearance.

(iii)

Dorsal extensions.

4.2

Labelling requirements

4.2.1 Lanyard assemblies and pole straps Unless supplied as an integral part of a harness where the following items are labelled on the harness, lanyard assemblies and pole straps shall be clearly and permanently labelleg. with the following information: (a)

Manufacturer's name, trade name or trademark.

( b)

Serial number.

(c)

Model and type/Identification.

(d )

Standard number and year of this Standard, i.e. AS 1891.5:2020.

(e)

Pictogram to indicate the necessity for users to read the instructions for use. (See Figure 4.1.)

   

Lanyard user capacity including clothing, tools kg 60 100 160

• J.

Figure 4.1 - Pictogram --- Read instructions before using (f )

The month and year of manufacture.

(g )

The month and year to remove from service which shall be no more than 10 years from the date of manufacture.

(h)

The words "The maximum allowable free-fall is 2 m".

(i)

The minimum and maximum user mass limits (required for lanyards only).

(j)

The lanyard capacity labelling requirements shall be written as follows: © Standards Australia Limited 2020 Bullivants | Page 209 of 692

AS 1891.5:2020

Minimum User Capacity: XX kg Minimum Fall Clearance: XX m Maximum User Capacity: XXX kg Minimum Fall Clearance: XX m 4.2.2 Connectors

Connectors shall be marked with the following: (a)

J( b)

Gate loading minimum breaking strength (gate face and gate side). Major axis minimum breaking strength .

See Clause 2.4.3 for minimum requirements.

4.2.3

Readability

Labelling shall be able to be read and identifiable (e.g. clearly distinguish individual letters or characters) throughout the life of the product.

AS 1892.1 :2018



Australian Standard® Portable ladders



Part 1: Performance and geometric requirements

Originated as part of AS 1892-1977. Previous editions AS/NZS 1892.1 :1996 and AS/NZS 1892.3:1996. Revised, amalgamated and redesignated as AS 1892.1 :2018.

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COPYRIGHT © Standards Australia Limited All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photoco ying, without the written permission of the publisher, unless otherwise permitted under the Copyright Act 1968. Published by SAi Global Limited under licence from Standards kustralia Limited, GPO Box 476, Sydney, NSW 2001, Australia ISBN 978 1 76072 182 4

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SECTION 2

GENERAL REQUIREM

AS il892.1:2018

NTS

2.1 DESIGN AND CONSTRUCTION

The design and construction shall be such that the ladder is of sufficient st ength, stiffness and stability to meet the performance requirements of this Standard. NOTE: Specific design and construction requirements are not a part of this Sta dard, because of the wide variety of materials and design possibilities.

2.2 RATINGS 2.2.1 Duty rating

Portable ladders shall be rated as either 'industrial' or 'domestic' in accor, ance with their designed service capability.

2.2.2 Load rating

Portable ladders shall have a load rating of(a)

(b)

not less than 120 kg for industrial ladders; or not less than 100 kg for domestic ladders.

2.2.3 Stability rating

Portable ladders may be rated as 'higher stability' in accordance with specific performance requirements. Refer to Appendices GG, HH and II. 2.3 MATERIALS 2.3.1 General

Materials should be durable and resistant to corrosion. Additionally, materials should be able to withstand handling under normal usage. Ferrous fittings or components may be made corrosion resistant by coating or plating. Materials used shall be compatible with respect to galvanic action.

NOTE: Guidance in the protection of iron and steel against exterior atmospheric corrosion is given in AS/NZS 2312 series. 2.3.2 Fibreglass

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2.3.2.1 General

Fibreglass should be a fully cured composite consisting of a co , mercial grade thermosetting isophthalic polyester resin reinforced with glass fibres. T e selection of polyester resin shall consider the following end use requirements: (a)

Electrical.

(c)

Outdoor weathering.

(b) (d) (e)



Corrosion resistance. Thermal conditions. Structural integrity.

I Resins and reinforcements, or combinations thereof, other than those specified in this Standard, may be used provided the ladder conforms to the releva+t performance requirements.

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AS 1892.1:2018

2.7 TREADS AND RUNGS

2.7.1 Size and shape

Treads and rungs shall conform to the following requirements for size and s

(a)

(b)

Treads and rungs shall present a working surface that will minimize t e possibility of slipping.

Working surfaces of rungs, steps, and platforms for use in ascendi g, descending, working or standing, shall be corrugated, serrated, knurled, dimpled, r coated with a skid-resistant material. r

They shall be of size and cross-sectional shape adequate in a cordance with Clauses 5.6, 10.4 and Appendices G, H, I, S, T, U and Z. �

NOTE: The size and sha�e of the working surface will also a�fect the com�ort and therefo�e the safety of persons workmg from ladders for extended periods. Accordmgly, the maximum practicable working surface is desirable.

2.7.2 Spacing

(a)

The spacing of treads and rungs shall comply with the following requirements: (b)



Treads and rungs shall be parallel with each other within ±2° .

Treads and rungs shall be uniformly spaced at a distance between centres within the range 248 ±2 mm to 306 ±2 mm (all measurements between the centres of the tops of treads and rungs).

The distance from the bottom ends of the stile, including feet where fitted, to the top of the first tread or rung shall be not less than 246 mm and not greater than the nominal tread or rung spacing.

For stepladders other than platform stepladders, treads shall be spaced so that the distances from the upper surface of the top cap, to the top of the highest tread or rung shall be equal (±8 mm) to the spacing of the treads or rungs.

2.8 MARKINGS AND SAFETY LABELS

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2.8.1 Identification

All ladders shall have the following information permanently marked in a prominent position: (a)

(b) (c)

The name of the Australian manufacturer or importer (whether the ladder has been made for sale or otherwise). The working length (in metres) of the ladder (the closed and ma I imum working lengths for extension type ladders).

Reference to this Standard and the duty rating (i.e. 'AS/NZS 1892.1 INDUSTRIAL' or 'AS/NZS 1892.1 DOMESTIC' as appropriate), and the words This ladder is intended to carry a maximum load of' and the load rating (in kilograms).

2.8.2 Safety labels

I Ladders shall have the following information permanently marked in a prominent position: (a) All ladders shall have a yellow exclamation symbol on an orange h�ader with word the 'WARNING' in black (see Figure 2.1), and text 'MISUSE OF A 1rADDER MAY RESULT IN A FALL, SERIOUS INJURY, PARALYSIS OR DEATH . 1

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AS 1892.1:2018

MISUSE OF A LADDER MAY RESULT IN A FALL, SERIOUS INJURY, PARALYSIS OR DEATH. FIGURE 2.1

WARNING LABEL

(b)

On metal ladders or ladders with electrically conductive stiles, add the words 'DO NOT USE WHERE ELECTRICAL HAZARD EXISTS'.

( c)

On double-sided stepladders, add the words 'TO BE USED IN THE FULLY OPEN POSITION ONLY'.

(d)

On those treads or rungs that would represent an unsafe working pdsition, a yellow exclamation symbol on a red header with word the 'DANGER' in white, and text 'DO NOT STEP' (see Figure 2.2) shall be added.

Such markings shall warn against standing any higher than the third top rung on a single or extension ladder, or the second top tread on stepladders (not including platform stepladders).

A DANGER

DO NOT STEP FIGURE 2.2 DANGER LABEL

NOTE: Other instruction or warning labels may be appropriate to illustrate correct setup, use and hazards associated with a particular type of ladder. Some example of additional• safety labels are given in Appendix C.

2.8.3 Label requirements All markings and safety labels shall comply with the requirements of Appbndix B. Safety labels applied to ladder components shall be as follows:

  

(a)

Permanent, taking into consideration the life of the product and the environment in which it is likely to be used.

(b)

Located to guard against wear, abrasion and disfiguring.

(c)

Attached by a method which does not affect the strength of the members to which I they are attached.

(d)

Legible and in letters not less than( i)

8 mm high in uppercase for the words 'DANGER', 'DOMESTIC' or 'INDUSTRIAL'; and

(ii)

4 mm high in uppercase or lowercase for the other words and numbers.

'WARNING',

NOTE: Suppliers are encouraged to use larger letter heights where practicablt

( e)

Able to be read by a person standing next to the ladder.

(f)

In a contrasting colour to the ladder colour.

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AS 1892.1:2018

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SECTION 3 PARTICULAR REQUIRE, ENTS FOR LADDERS CONFIGURED AS SI GLE LADDERS 3.1 LENGTH

The maximum length of a single ladder, shall not exceed



(a)

9 m for industrial ladders; or

(b)

5 m for domestic ladders.

3.2 DISTANCE BETWEEN STILES

The clear distance between the inside faces of the stiles or the width of the orking surface I of the rungs shall be not less than 265 mm (see Figure 3.1). If the stiles are flared (see Clause 2.6), this dimension shall apply to the portion of the ladder above the flare. NOTE: The 265 mm distance is the minimum clear distance between the stiles, not the length of the rung.

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I I I I I I I I I I I I I I I I 1 I I I I I

I I I 1 1 I l I l I I l I 1 I I I I I I l I

I I LJ I I 1 I I I I I I I I I I I I I I I I I I I

I! LJ I I 1 1 I I I l I! I I I I I I 1 I 1 I I I

r-,-t-----------t- r,

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265 mm

FIGURE 3.1

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I I I I I I I I I I I I I I I I I I I I I I -r , I I _LJ I I I I I I I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I I I I I I r-i 1 I LL I I I I I I I I I I I I I I I I I I I I I I

265 mm

DISTANCE BETWEEN STILES

3.3 PERFORMANCE

Single ladders and other ladders when configured as single ladders shall be ubjected to the performance tests in, and shall comply with the performance criteria in, the Appendices listed in Table 3.1.

 www.standards.org.au

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AS 1892.1:2018

SECTION 4 PARTICULAR REQUIRE, ENTS FOR LADDERS CONFIGURED AS EXT NSION LADDERS 4.1 LENGTH The maximum length of an extension ladder, including feet, shall not excee -



(a)

15 m for industrial ladders; or

(b)

7 m for domestic ladders.

4.2 EXTENSION OF STILE ABOVE TOP RUNG Except for those ladders fitted with a pole chain, hoop, or similar device, the distance between the top rung and the top of the ladder, when measured axially along the centre-line of the ladder, shall not exceed 308 mm. 4.3 DISTANCE BETWEEN STILES The clear distance between the inside faces of the stiles or the width of the working surface of the rungs in the narrowest section of the ladder, shall be not less than 265 mm (see Figure 3.1).

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4.4 OVERLAP Care shall be taken to ensure that the rungs on overlapping sections coincide. 4.5 STOPS The ladder shall be designed so that it cannot be over extended. 4.6 FITTINGS

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4.6.1 Finish Fittings shall have no sharp edges liable to cause indentation to stiles or rungs. 4.6.2 Fixed hooks Fixed hooks shall-

 

(a)

have an effective length (A) over the rungs of not less than the de th of the rung (see Figure 4.1); and

(b)

bear evenly on the rung and with a total bearing width of not less than 12 mm.

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AS 1892.1:2018

L A

A - effective length of

hook over the rung

FIGURE 4.1

FIXED HOOK

4.6.3 Latching devices Ladders in which the upper section(s) are raised or lowered by rope shal be fitted with latching devices that(a)

operate to engage automatically if the rope breaks or is released;

(b )

are not dependent for their operation on a spring;

( c)

bear evenly on the rung and with a total bearing width of not less than 12 mm;

(d)

operate dynamically with the ladder at an angle of not less than 70 ° and statically at an angle of 90° above the horizontal; and

(e)

are designed so as to maintain the top and bottom sections of the ladder in a relative position such that the working surface of rungs at the overlap form double working surfaces at every intended stage of extension.

4.6.4 Guide brackets

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Guide brackets, where used, shall be attached securely and positioned so as to prevent the upper section from tipping or falling out while being raised or lowered, or while the ladder is being used. 4.7 LIFTING DEVICES 4.7.1 General

 

Where the maximum length of an extension ladder is greater than 5 m, the ladder shall be. equipped with a hauling rope and pulley or suitable device to enable an op -rator at ground level to raise the top section or intermediate sections. 4.7.2 Load The fittings and rope should be capable of withstanding an ultimate load tha would support at least 10 times the mass of the movable section(s) of the ladder.

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AS 1892.1:2018

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SECTION 5 PARTICULAR REQU1RE FOR LADDERS CONFIGURED A STEPLADDERS

ENTS

5.1 LENGTH



The length of a stepladder measured along the front edge of the stiles, incl ding feet, shall not exceed(a)

(b)

6.1 m for industrial ladders; or

2.4 m for domestic ladders.

5.2 DISTANCE BETWEEN STILES

The front section of single-sided stepladders and both sections of double-s · ded stepladders shall be designed so that the clear distance between the inside faces of the stiles at the tread immediately below the top cap is not less than 290 mm, and either-

(a)

(b)

 



the stiles flared out at the bottom to increase stability.

For tapered ladders described in Item (a) above, the distance between stiles shall increase by not less than 125 mm per metre length of stile. For flared ladders described in Item (b) above, the distance between the bottom of the stiles shall be equivalent to that for a tapered ladder of the same length. 5.3 BACK LEGS

The following requirements apply to back legs:

(a)



the distance between the stiles varies uniformly along the length (i.e. tapered stepladder); or

(b) (c)

(d)

(e)

Shall be constructed and braced so that the stepladder is stable when in the fully open locked position.

For single-sided stepladders, shall be braced in a manner that does not encourage the bracing to be used for ascending or descending.

Shall be hinged by a means that is at least equivalent in strength (sing�e shear), wear, and cross-section to low carbon steel pivot pins of 8mm diameter. N�jither the back legs nor the stiles shall bear on any threaded portions of pivot pins. Nuts, if used, shall be effectively locked. Tubular or hollow-section rivets shall not tie used as pivot pins. , · 1 For ladders designed to be used in the closed position, shall be of such length that when the ladder is laid against a wall in the fully closed position w·1 h the working surfaces horizontal, it is supported fully on the front stiles or feet.

When folded, they shall not cause damage to the stiles, treads, or sprea er bars.

5.4 SPREAD BETWEEN STILES AND BACK LEGS

With the ladder in the fully open position, the clear distance between the rear edge of the stiles and the front edge of the back legs shall be not less than 500 mm and ot greater than 660 mm per metre length of stile.

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AS 1892.2—1992

Australian Standard® Portable ladders Part 2: Timber

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AS1892.2:1992 Page SECTION 8 8.1 8.2 8.3 8.4 8.5

22 LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STILES ..................................................................................................................22 TREADS AND RUNGS ........................................................................................22 FITTINGS ..............................................................................................................23 TOP ........................................................................................................................23

SECTION 9 9.1 9.2 9.3

PARTICULAR REQUIREMENTS FOR DOMESTIC EXTENSION STEPLADDERS

TIMBER LADDERS HAVING STILES OF TIMBER OTHER THAN DOUGLAS FIR

APPLICATION .......................................................................................................... 24 MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

APPENDICES 25 29 31

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A METHODS OF GRADING TIMBER STILES . . . . . . . . . . . . . . . . . . . . . . . . . . B EXAMPLES OF LABELS USED FOR ADDITIONAL SAFETY WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C DERIVATION OF EQUATIONS FOR EXTREME FIBRE STRESS . . . . . . . . .

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AS1892.2:1992 AS 1892.2—1992

2.6 TREADS AND RUNGS 2.6.1 Shape Treads and rungs shall present a bearing surface that will minimize the possibility of slipping. NOTE: Those surfaces of rungs, steps, and platforms for use in ascending, descending, working, or standing should be skid-resistant.

2.6.2 Spacing The spacing of treads and rungs shall comply with the following requirements: (a) Treads and rungs shall be parallel to each other within ±2 mm. (b) Treads and rungs shall be uniformly spaced at 300 ±8 mm centres. (c) The distance from the bottom ends of the stile including feet where fitted, to the top of the first tread shall be 300 ±8 mm. 2.7 MARKING 2.7.1 All ladders All ladders shall have the following information permanently marked in a prominent position: (a) The name of the manufacturer (whether the ladder has been made for sale or otherwise). (b) In the largest lettering practicable, the duty rating (i.e. ‘Industrial’ or ‘Domestic’ as appropriate), and the load rating in kilograms. (c) The working length of the ladder (the closed and maximum working lengths for extension type ladders). (d) A warning against standing on those treads or rungs which would represent an unsafe working position. Such marking shall warn against standing any higher than— (i) on a stepladder: the second top tread; or (ii) on a single or extension ladder: the third top rung. NOTE: Manufacturers making a statement of compliance with this Australian Standard on a product, packaging, or promotional material related to that product are advised to ensure that such compliance is capable of being verified.

2.7.2 Double-sided stepladders In addition to the requirements of Clause 2.7.1, double-sided stepladders shall have the following words permanently marked in a prominent position: ‘To be used in the fully open position only’. 2.7.3 Wire bound ladders In addition to the requirements of Clause 2.7.1, wire bound ladders shall have the following words permanently marked in a prominent position, and in the largest lettering practicable: ‘Do not use where electrical hazard exists’. 2.7.4 Labels Labels used for marking shall be located to guard against wear, abrasion, and disfigurement, and shall be attached by a method which does not affect the strength of the members to which they are attached.

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NOTES: 1 Labels are not considered satisfactory unless appropriately located or protected. 2 Examples of labels used to illustrate additional safety warnings are given in Appendix B.

FIGURE 2.1 FOOT FRICTION TEST

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AS/NZS 1892.3:1996

Australian/New Zealand Standard Portable ladders Part 3: Reinforced plastic

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AS1892.3:1996

Page

SECTION 6 PARTICULAR REQUIREMENTS FOR TRESTLE LADDERS 6.1 LENGTH ............................................................................................................. 21 6.2 SPACING OF CROSS-BEARERS .......................................................................... 21 6.3 DISTANCE BETWEEN STILES ......................................................................... 21 6.4 SPREAD BETWEEN PAIRS OF STILES ........................................................... 21 6.5 SPREADER ......................................................................................................... 21 6.6 HINGES ............................................................................................................... 22 6.7 CHECK BLOCKS .................................................................................................... 22 6.8 PERFORMANCE ................................................................................................. 22 SECTION 7 PARTICULAR REQUIREMENTS FOR MULTIPURPOSE LADDERS 7.1 LENGTH ............................................................................................................. 23 7.2 DISTANCE BETWEEN STILES ......................................................................... 23 7.3 ANGLE BETWEEN STILES . ....................................................................................23 7.4 ARTICULATION ................................................................................................ 23 7.5 PERFORMANCE ................................................................................................. 23 SECTION 8 PARTICULAR REQUIREMENTS FOR OTHER LADDERS 8.1 SCOPE OF SECTION ............................................................................................. 24 8.2 REQUIREMENTS ............................................................................................... 24

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SECTION 9 PERFORMANCE REQUIREMENTS 9.1 GENERAL ........................................................................................................... 25 9.2 PERFORMANCE REQUIREMENTS FOR SINGLE AND EXTENSION LADDERS ..................................................................................... 25 9.3 PERFORMANCE REQUIREMENTS FOR STEPLADDERS AND TRESTLE LADDERS .......................................................................................... 26 9.4 PERFORMANCE REQUIREMENTS FOR MULTIPURPOSE LADDERS . . 27 9.5 DESIGN VERIFICATION TESTS ......................................................................... 28 9.6 TESTS FOR LABELS ............................................................................................. 29 APPENDICES A TYPICAL PHYSICAL AND MECHANICAL PROPERTIES . . . . . . . . . . . . B TESTS FOR LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C EXAMPLES OF LABELS USED FOR ADDITIONAL SAFETY WARNINGS D STILE DEFLECTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E ANGULAR DEFLECTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F HORIZONTAL BEND STRENGTH TEST . . . . . . . . . . . . . . . . . . . . . . . . . G RUNG TORQUE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H RUNG STRENGTH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I RUNG SHEAR STRENGTH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J SIDE SWAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K STILE CANTILEVER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L FOOT FRICTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M DYNAMIC DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N LADDER SECTION TWIST TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O LATCHING DEVICE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P EXTENSION LADDER FITTINGS AND FOOT DISTORTION TEST . . . . .

30 32 33 36 39 41 43 45 47 49 51 54 56 58 60 61

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AS1892.3:1996 Page

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Q R S T U V W X Y Z AA AB AC AD AE AF

LADDER COMPRESSION AND FOOT DISTORTION TEST . . . . . . . . . . . STILE BENDING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TREAD BENDING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TREAD-TO-STILE SHEAR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TREAD TORQUE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STABILITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WALKING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STILE AND BACK LEG CANTILEVER TEST . . . . . . . . . . . . . . . . . . . . . STEPLADDER DYNAMIC DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . MULTIPURPOSE WORK PLATFORM BENDING TEST . . . . . . . . . . . . . . CYCLIC HORIZONTAL BENDING TEST . . . . . . . . . . . . . . . . . . . . . . . . STILE SHEAR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYCLIC STILE-BENDING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYCLIC JOINT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNLOCKED JOINT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINGLE JOINT LOCK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 66 69 72 74 76 78 80 83 85 86 88 90 92 93 94

Originated in New Zealand as part of NZS 5233:1981. Previous edition 1986. Jointly revised and redesignated in part as AS/NZS 1892.3:1996.

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AS1892.3:1996 (b)

They shall be of a suitable size and cross-sectional shape adequate to comply with Section 9. NOTE: The size and shape of the working surface will affect the comfort and therefore the safety of persons working from ladders for extended periods. Accordingly, the maximum practicable working surface is desirable.

FIGURE 2.1 EXAMPLES OF MINIMUM AREA OF FEET (HATCHED) FOR DIFFERENT SECTION OF STILE OR LEG

2.7.2 Spacing requirements:

The spacing of treads and rungs shall comply with the following

(a)

Treads and rungs shall be parallel with each other within ±2 degrees

(b)

Treads and rungs shall be uniformly spaced at a distance between centres within the range 248 ±2 to 306 ±2 mm. Measurements may be made at any position.

(c)

The distance from the bottom ends of the stile including feet where fitted to the top of the first tread or rung shall be equal to the nominal tread or rung spacing.

(d)

For stepladders other than platform stepladders, treads shall be spaced so that the distances from the upper surface of the top cap to the top of the nearest tread or rung shall be equal (±8 mm) to the spacing of the treads or rungs (all measurements along the stiles).

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2.8 MARKING All ladders shall have the following information permanently marked in a prominent position: (a)

The name of the Australian manufacturer or importer (whether the ladder has been made for sale or otherwise).

(b)

In the largest lettering practicable, the duty rating (i.e. ‘INDUSTRIAL’ or ‘DOMESTIC’, as appropriate), the words: ‘This ladder is intended to carry a maximum load of’ and the load rating in kilograms.

(c)

The working length of the ladder (the closed and maximum working lengths for extension type ladders).

(d)

On double-sided stepladders, the words ‘TO BE USED IN THE FULLY OPEN POSITION ONLY’.

(e)

A warning against standing on those treads or rungs which would represent an unsafe working position. Such marking shall warn against standing any higher than— (i)

the second top tread or on a stepladder not being a platform stepladder; or

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AS1892.3:1996 (ii)

the third top tread on a single or extension ladder.

Labels used to illustrate such marking shall comply with the requirements of Clause 9.6 and Appendix B and shall be located to guard against wear, abrasion and disfiguring. Labels shall be attached by a method which does not affect the strength of the members to which they are attached. NOTES: Labels are not considered satisfactory unless appropriately located or protected.

Examples of labels used to illustrate additional safety warnings are given in Appendix C (Figures C1, C2 and C3).

Manufacturers making a statement of compliance with this Australian Standard on a product, packaging, or promotional material related to that product are advised to ensure that such compliance is capable of being verified.

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AS 1892.5:2020

Austmlian

DARO

Portable ladders Part 5: Selection, safe use and care

Originated as AS CA29-1959. Previous edition AS/NZS 1892.5:2000. Revised and redesignated as AS 1892.5:2020.

•

COPYRIGHT © Standards Australia Limited 2020 All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical , including photocopying , without the written permission of the publisher, unless otherwise permitted under the Copyright Act 1968 (Cth).

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AS 1892.5:2020

11 •

Section 3 3.1

Metal ladders

Electrical hazards

M etal ladders, including step and trestle ladders, shall no t be used where a electrical hazard exists. W,hen handling a metal ladder, care shall be taken to ensure that the ladder d es not make contac t with powerlines and conductors.

3.2

Maintenance

Metal ladders should be checked frequently and maintained in a good condition. All pivo ting or rotating surfaces should be lubricated with suitable lubricant, or lubricant according to the manufacture's specifications. Fastners and rivets should be present and secure before the ladder is used. If a fastener or rivet is found to be loose or missing, the ladder should not be used until repairs are completed. Ladder feet that are excessively worn or missing should be replaced before use. Ropes. showing sign of fraying, wear, rot or other damage should be replaced. Under no circumstances shall any temporary repairs be made to a metal ladder. Broken or bent ladders or ladders with parts missing shall be marked and taken out of service until .they are repaired by a competent person or destroyed in such a manner as to render them useless, e.g. by cutting into leng ths of approximately 1 m, or not more than two rungs. Repairs carried out to ladders shall not weaken the ladder from the original design specification.

3.3 Inspection A thorough ladder inspection should be made (a)

when originally purchased, received and put into service;

(b)

before each use;

(c)

af ter mishaps, drops and impacts; and

(d)

periodically.

Metal ladders should be checked for internal corrosion, loose rung or tread-to-stile connections, and deformed flanges. Where a defect is found, the ladder shall be marked and taken out of service for either repair by a competent person or destruction. NOTE A ladder register may be appropriate to record and track inspections�

3.4 Tipping over, and other impact damage Where a metal ladder has been tipped over or has been exposed to impact, it shall be inspected for dents, bends, damage (e.g. distortion), deformed flanges or excessively dented rungs. All rung or tread-to-stile connections shall be checked, as well as hardware connections, �ivets (for shear) and all other components.

3.5

Exposure to fire

If ladders are exposed to excessive heat, such as that from fire, their strength · may be reduced. After such exposure, steel ladders shall be inspected visually for damage and tested for deflection and strength characteristics before further use, refer to AS 1892.1. Aluminium ladders should be discarded.

Bullivants | Page 238 of 692

•

AS 1892.5:2020

3.6 Corrosive substances When metal ladders are to be exposed to a corrosive environment that could signif�cantly reduce the working load, product life or other performance properties (e.g. deflection under load: of the ladder, the manufacturer or a competent person shall be consulted prior to such exposure.

3.7 Storage Metal ladders should be stored in or on racks designed to protect the ladder when it is not in use, preferably under cover. These racks should have enough supporting points to avoid sagging. Material should not be placed on the ladder while the ladder is in storage.

•

• •

0) ·,_

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AS 1892.5:2020

Section 4 4.1

Non-metallic ladders

Maintenance

Non-metallic ladders should be maintained in a good condition, and be clea and free from splinters and fibres. Fittings and rungs · or treads should be tight and securely attach d. Pivoting and rotating components should be suitably lubricated, and all moving parts should opera ,e freely without bending or play. Ropes showing signs of fraying, wear, rot or other damage should be r�placed. I

Under no circumstances shall any temporary repairs be made to a non-metallic, ladder. If the surface of a reinforced plastic ladder has degraded (e.g. as a result of exposure to ultraviolet radiation), some reinforcing fibres may become exposed. The ladder stiles should be washed with a commercial solvent or liquid detergent solution compatible with the stile material and allowed to air dry. The stile should be coated with a polyurethane or acrylic lacquer. More than one coat of lacquer may be required to fully encapsulate the exposed fibres. •

Broken, cracked, delaminated, split, fractured, crushed or bent ladders or ladders with parts missing shall be marked and taken out of service until they are repaired by a competent person or destroyed in such a manner as to render them useless, e.g. by cutting into lengths of approximately 1 m, or not more than two rungs.. Repairs carried out to ladders shall not weaken the ladder from the original design specification. NOTE Due to the complexity of design, material specification and the requirement for electrical non conductivity, refer to the original manufacturer or importer for advice or information prior to starting any repairs to damaged stiles.

4.2

Inspection

A thorough ladder inspection should be made ( a)

when originally purchased, received and put into service;

( b)

before each use;

(c)

after mishaps, drops and impacts; and

(d )

periodically.

•

Non-metallic ladders should be checked for internal corrosion and loose rung or tread-to-stile connections. Where a defect is found, the ladder shall be marked and taken out of service for either repair by a competent person or destruction.

4.3

Tipping over, and other impact damage

Where a non-metallic ladder has been tipl}ed over or exposed to impact damage, it shall be inspected for splits, cracks, delaminations, dents or bends, or excessively dented rulilgs. All rung or tread to-stile connections shall be checked, as well as hardware connections, rivets ( for shear) and all other components.

4.4 Exposure to fire If non-metallic ladders are exposed to excessive heat, such as that from fire, their strength may be reduced. After such exposure, ladders shall be inspected visually for damage and tested for deflection and strength characteristics before further use, refer to AS 1892.1.

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AS 1892.5:2020

4.5

Corrosive substances

When non-metallic ladders are to be exposed to a corrosive environment that could si nificantly reduce the working load of the ladder, the manufacturer or a competent person shall be <1=onsulted prior to such exposure.

4.6 Storage Non-metallic ladders should be stored .in or on racks designed to protect the ladder w en it is not in use, preferably under cover. These racks should have enough supporting points to avoid sagging. Material should not be placed on the ladder while the ladder is in storage.

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Section 5 5.1

AS 1892.5:2020

Timber ladders

Electrical hazards

Timber ladders using exposed wire reinforcement in the stiles shall not be sed where an electrical hazard exists.

5.2

Hot conditions

Timber ladders should not be placed where they may be subjected to prolonged exposure to temperatures greater than 66 °C.

5.3

Maintenance

Timber ladders should be maintained in a good condition, and be clean and free from splinters, spilt paint or other opaque deposits. Fittings and rungs or treads should be tight and securely attached. Pivoting and rotating components should be lightly oiled, and all moving parts should operate freely without bending or play. Ropes showing signs of fraying, wear, rot or other damage should be replaced . '

Under no circumstances shall any temporary repairs be made to a timber ladder. Broken, split or bent ladders, ladders with parts missing or otherwise damaged. shall be marked and taken out of service until they are repaired by a competent person or destroyed in such a manner as to render them useless, e.g. by cutting into lengths of approximately 1 m or not more than two rungs. Repairs carried out to ladder stiles shall not weak�n the ladder from the original design specification . N.OTE Due to the complexity of design, material specification and the requirement for electrical non-

conductivity refer to the original manufacturer or importer for advice or information prior to starting any repairs to damaged stiles.

5.4 Coating of stiles Regular application of oil, transparent varnish or other similar protective coating should be made to the stiles of timber ladders, especially where the ladder is to be used outdoors. Such coatings, including spilt paint or mortar, should not be allowed to build up to the extent that they may obscure compression failure or other defects that may occur.

5.5 Inspection

•

A thorough ladder inspection should.be made (a) ·

when originally purchased, received and put into service;

( b)

before each use;

(c)

after mishaps, drops and impacts; and

(d)

periodically.

Timber ladders should be checked for shakes in the timber, loose rungs or treaqs, twisting and racking, evidence of termites, borers and decay, and corrosion of metal parts. Where a d�fect is found, the ladder shall be marked and taken out of service for either repair by a competent person or destruction.

5.6 Tipping over, and other impact damage Where a timber ladder has been tipped over or expo-sed to impact damage, it shall be inspected for damage such as splits, chips, fractures, compression failures, dents or bends, or excessively dented Bullivants | Page 242 of 692

AS 1892.5:2020

rungs. All rung or tread-to-stile connections shall be checked, as well as hardware onnections, rivets · (for shear) and all other components.

5. 7 Corrosive substances When timber ladders are to be exposed to a corrosive environment that could si;nificantly reduce the working load of the ladder, the manufacturer or a competent person shall be I onsulted prior to such exposure. •

5.8 Storage Timber ladders should be stored in or on racks designed to protect the ladder when it is not in use, preferably under cover. These racks should have sufficient supporting points to avoid sagging. Material should not be placed on the ladder while the ladder is in storage. I Timber ladders should be stored in well-ventilated places and protected from the weather, decay and insect attack. Places that are damp or subject to extremes of temperature should not be used for storage purposes.

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AS 2076—1996

Australian Standard Wire-rope grips for non-lifting applications

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AS 2076—1996

MARKING AND INSTRUCTIONS

8.1 Marking The bridge of each wire-rope grip shall be permanently and legibly marked with the nominal size (see Clause 5), the marking being either raised or indented. Where it is indented, care shall be taken to ensure that the marking is neither too sharp nor too deep. The size of marks should be as follows: millimetres Nominal size of wire-rope grip

Minimum size of mark

≤12

>12 ≤25

>25

NOTE: Manufacturers making a statement of compliance with this Australian Standard on a product, packaging or promotional material related to that product are advised to ensure that such compliance is capable of being verified.

Accessed by RMIT UNIVERSITY LIBRARY on 24 Apr 2002

8.2 Instructions Any installation instructions for wire-rope grips should include the following information: (a)

That the wire-rope grips may be used on six-stranded 6 × 19 or 6 × 36 construction 1570 or 1770 grade steel wire ropes, without further testing.

(b)

That where wire-rope grips are to be used on other constructions or other grades of rope, further type testing is required (see Clause 9).

(c)

The correct method of application (see Figure 10.5).

(d)

The length of rope to be placed in a turnback.

(e)

The number of wire-rope grips to be used for each rope size, which shall comply with Clause 10.5.

(f)

The order of installation of the wire-rope grips.

(g)

The recommended spacing between the wire-rope grips (see Clause 10.5).

(h)

The torque to be used for tightening the nuts.

(i)

Any checking and retightening that is required after the first loading.

9 TESTING OF MECHANICAL PROPERTIES requirements of Clause 7 shall be demonstrated.

Compliance of each design with the

NOTES: 1

The test of each design is known as the type test, which determines the adequacy of the design for achieving the required performance.

Each change in the manufacturing process, grade of material, design and size necessitates separate type testing, to demonstrate compliance with the requirements of Clause 7.

In addition to type testing, effective quality control necessitates systematic testing of each lot or batch to ensure continuing compliance with the requirements of Clause 7.

Means for demonstrating compliance with this Standard are given in Appendix E.

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AS 2076—1996

CARE AND USE OF WIRE-ROPE GRIPS

10.1 Inspection A termination made with wire-rope grips shall be inspected at regular intervals. The preferred frequency of inspection is after each loading. In most applications, it will be found that the nuts require further adjustment. 10.2 Use Properly applied wire-rope grips afford a simple mechanical means of securing the end of a steel-wire rope. They are appropriate for temporarily securing the end of a steel-wire rope that may need to be shortened. They should not be used to secure a rope that is later to be lengthened from the gripped end (see Clause 10.4). Wire-rope grips are not intended for the permanent fastening of a rope that is subject to high dynamic loading. Wire-rope grips shall not be used for lifting purposes. Also, wire-rope grips shall not be used for rope terminations on load suspension devices that are used for lifting. Where wire-rope grips are fitted to ropes constructed of higher-grade wire than that described in Appendix D, the assembly may need to be derated to reflect the lower capacity of the wire-rope grips, or additional wire-rope grips may be required. Any manufacturer’s recommendations should be complied with (see also Item (b) of Clause 8.2). 10.3 Live running ropes Wire-rope grips shall not be used for making terminations on live running ropes (i.e. one that applies force to a moving object) nor where the rope is required to support persons or suspended loads. 10.4 Rope lengthening Wire-rope grips should not be used where there is a likelihood of the rope having to be lengthened at that end. Lengthening would bring at least part of the rope on which the wire-rope grip had been fastened into a position that is subject to full load. The danger is that this part of the rope may have been damaged by the effects of fatigue or by pressure exerted by the wire-rope grip. 10.5 Method of application The effectiveness of a wire-rope termination made with wirerope grips depends upon ensuring the required number of wire-rope grips are used, and the spacing, orientation, placement and tightening of the grips are done in accordance with this Standard. For wire ropes of intermediate sizes, the next larger size of wire-rope grip shall be used.

Accessed by RMIT UNIVERSITY LIBRARY on 24 Apr 2002

The number of wire-rope grips per connection shall be not less than the minimum specified in Table 1. If the manufacturer or supplier recommends a greater number of wire-rope grips per connection than the minimum specified in Table 1, this recommendation shall be followed. Grips with u-bolts shall be fitted to a wire rope as shown in Figure 2, but not as shown in Figure 3. The bridge shall be fitted on the working part of the rope and the u-bolt bearing on the tail end of the rope. Wire-rope grips shall not alternate in orientation on the rope. The wire-rope grips in a connection should be spaced along the wire rope at distances of approximately six rope diameters, with the position of the one nearest the end connection as shown in Figure 2 to be as close as possible to, but not less than one rope diameter from, the end fitting. Where a round thimble is used (see Figure 2(b)), the distance between the round thimble and the first wire-rope grip should be not less than twice the diameter of the rope. The sequence of tightening an assembly of wire-rope grips on a wire-rope connection after they have been correctly positioned is from the thimble outwards. The tightening torque shall be achieved on greased bearing surfaces of the nuts. With improperly tightened nuts, or with fewer grips than the number recommended, the end of the rope might draw through the wire-rope grips even due to a light loading. The wire-rope grips furthest from the eye of the thimble should not be overtightened as that position is the most vulnerable part of such an assembly. The tightening torque applied to the nuts shall

Bullivants | Page 246 of 692

AS 2076—1996 comply with any instructions provided by the manufacturer or supplier; however, where instructions are not provided by the manufacturer or supplier, the tightening torque applied to the nuts shall be the relevant value that is listed in Table 1.

CORRECT METHOD OF FITTING WIRE-ROPE GRIPS

FIGURE 3

INCORRECT METHOD OF FITTING WIRE-ROPE GRIPS

Accessed by RMIT UNIVERSITY LIBRARY on 24 Apr 2002

FIGURE 2

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AS 2089—2008

Australian Standard® Sheave blocks for lifting purposes

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AS 2089—2008 (f)

The positioning of bottom fittings and top fittings shall not impede the running of the rope.

5.4 Hinged side straps Hinge pins for hinged side straps on snatch blocks shall have a strength that is sufficient to support half the resultant load that may be applied to the head fitting of the block. Hinged flaps shall be secured to the crosshead in the closed position by means of a locking pin and chain, or by other effective means. Allowance shall be made for any bending moment that may be induced in the strap by an offset of the hinge pin. 5.5 Rotating side plates Screw type snatch pins used on rotating side plates should have provision for a locking pin. 5.6 Sheaves

5.6.1

Manufacture

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The following requirements apply to sheaves: (a)

Sides of rope grooves shall have adequate strength to withstand safely any shear and bending loadings that would be induced by flattening of the rope under load or by the rope feeding off line from the groove (i.e., with a fleet angle).

(b)

Faces of sheave bosses shall be normal to the axle, smoothly finished and free from surface defects.

(c)

The rims of sheaves shall not make contact with the side plates.

(d)

The clearance between the sheave and the side plates and partition plates shall be such that the rope used with the block cannot pass or jam between them.

5.6.2

Diameter

The ratio of the diameter of the sheave at the bottom of the rope groove to the nominal size of the rope to be used with the sheave shall be not less than the following relevant value: (a)

(b)

Where reeved with steel-wire ropes for lifting applications— (i)

for hand-operated blocks—10; and

(ii)

for power-operated blocks—the relevant ratio listed in Table 4.

Where reeved with fibre rope—5.

NOTE: Guidance on non-lifting applications is given in Appendix D.

5.6.3

Rope groove

Rope grooves on sheaves, as defined in Figure F1, Appendix F, shall comply with the following requirements: (a)

Rope grooves shall be at right angles to the axis of the bore and shall comply with Appendix F.

(b)

The surface of rope grooves and outside rims shall be smoothly finished and free from surface defects that are liable to cause damage to rope. The edges of rims shall be rounded.

(c)

Where used with natural fire rope or synthetic filament rope, the depth of rope grooves shall be not less than 0.32 times the diameter of the rope and the bottom of rope grooves shall be the arc of a circle with a radius of not less than 0.57 times the diameter of the rope.

(d)

For use with wire rope— (i)

the depth of rope grooves shall be not less than the diameter of the rope;

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AS 2089—2008 (ii)

the bottom of rope grooves shall be an arc of a circle with a radius of not less than 0.535 times nor more than 0.585 times the diameter of the rope, except that where the diameter of the rope is less than 7 mm, an upper limit of 0.615 times the diameter of the rope shall apply; and

(iii)

the sides of rope grooves shall be tangential to the bottom arc and flared with an included angle of not less than 30° that is symmetrical about the centre-line of the groove.

NOTES: 1

For general purposes, the included angle should be not more than 60°.

A sheave block may also be required to comply with the relevant requirements of AS 1418.1.

AS 1418.1 defines different groove profiles for wire rope sheaves, which may be suitable for some applications.

TABLE 4

Accessed by Wesfarmers Industrial and Safety Ltd on 09 Mar 2018 (Document currency not guaranteed when printed)

MINIMUM RATIOS OF SHEAVE ROOT DIAMETER TO STEEL-WIRE ROPE DIAMETER Classification (see Note 1)

Minimum ratio of sheave root diameter to steel-wire rope diameter

M1 M2 M3

11.5 13.0 15.0

M4 M5 M6

17.0 19.0 21.4

M7 M8

24.0 27.0

NOTES:

This is the group classification of crane mechanisms that is specified in AS 1418.1.

The preferred sizes of sheaves are listed in Appendix F.

For applications covered by AS 1418.1, the ratio of the sheave diameter to the wire rope diameter shall conform to that Standard.

5.7 Head fittings

5.7.1

Forged head fittings

Where a fitting is provided for which there is no suitable Australian Standard, it shall not be subjected to stresses greater than those permitted by any equivalent Australian Standards for lifting tackle. Hooks shall be in accordance with AS 3777. Provision of a latch shall be in accordance with AS 3777.

5.7.2

Crosshead, hanger straps, eyes, and similar head fittings

Crossheads, hanger straps, link plates, eyes and similar head fittings shall be manufactured by one of the following methods: (a)

Cast or forged in one piece to the finished shape, followed by any necessary machining.

Bullivants | Page 250 of 692

AS 2089—2008 5.12 Finish Any roughness and sharp edges on the surfaces of sheave block components that may impair the strength of a rope or create a handling hazard shall be removed. 5.13 Surface finish The surface finish shall be one of the following: (a)

Self-coloured (see Clause 3.4).

(b)

Hot-dipped galvanized coating complying with AS 4680.

(c)

Class A1, Class A2, or Class B phosphate coating complying with AS 1627.6.

(d)

Fe/Zn 12c electroplated zinc coating complying with AS 1789.

(e)

Fe/Cd 12c electroplated cadmium coating complying with AS 2082.

(f)

Painted coatings. NOTE: AS 1627.0 gives guidance for preparing steel surfaces for painting.

(g)

Any other surface finish that does not cause a degradation of the mechanical properties of the finished product.

Accessed by Wesfarmers Industrial and Safety Ltd on 09 Mar 2018 (Document currency not guaranteed when printed)

NOTE: Hydrogen embrittlement can occur in steels that are quenched and tempered or cold worked, because of the absorption of atomic hydrogen generated at the steel surface by processes such as acid pickling, cathodic cleaning and plating.

5.14 Lubrication Except where inherent characteristics of the bearing material obviate the necessity for an external means of lubrication, lubrication points for bearings shall be provided in locations where they are not unnecessarily exposed to accidental damage and where they may be lubricated without the block being dismantled. Rolling element bearings shall be pre-packed with grease during initial assembly and sealed in a manner that will prevent the ingress of deleterious matter. 5.15 Other standards NOTE: Other standards relevant to the design and manufacture of sheave blocks are listed in Appendix G.

6 MECHANICAL PROPERTIES 6.1 Strength Each sheave block shall be capable of supporting a test load of 5 times its working load limit (WLL) under the conditions specified in Appendix H provided that, where a hook is incorporated in the sheave block, the hook shall comply with AS 3777 (which requires a safety factor of 4:1 for higher tensile hooks). The WLL shall be not greater than the value determined by the relevant formula in Table 5. 6.2 Rotation Where the head fitting is intended to swivel under load during normal use, the head fitting shall be able to be rotated while loaded to 1.25 times the working load. NOTE: This may be demonstrated by suspending this load and rotating it by hand alone.

7 MARKING Sheave blocks shall be permanently and legibly marked with the following information: (a)

Manufacturer’s identification.

(b)

Nominal size of rope.

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AS 2089—2008 (c)

Rope material (e.g., natural fibre, polyethylene, polypropylene, wire).

(d)

The material, grade and construction of the rope, where the sheave block is intended for rope other than 1770 IWR construction (as specified in AS 3569).

(e)

Where the sheave block has a becket, the WLL shall be stated both for ‘with becket’ and for ‘without becket’.

(f)

Identification marking to correlate the sheave block to the test certificate.

TABLE 5 WORKING LOAD LIMIT (WLL) Type of sheave block

Accessed by Wesfarmers Industrial and Safety Ltd on 09 Mar 2018 (Document currency not guaranteed when printed)

tonnes 2NP 9.81K

Without becket

With becket (see Notes)

WLL of sheave block

Not using becket Using becket (see Note 1)

2NP 9.81K

(2N + 1)P 9.81K

LEGEND: N = number of sheaves (see Note 2) P = minimum breaking force of rope, in kilonewtons K = 5 [K is the design factor of rope (see Note 3)] NOTES: 1

When a becket is rigged, the becket increases the load on the head fitting by the line pull on the wire rope, thereby increasing the mechanical advantage by one fall of rope.

This Table applies where the block has less than 10 parts of rope. A more detailed calculation is necessary where the block has 10 or more parts of the rope.

For the purposes of this Standard, the WLL of wire rope is taken to be 20% of the minimum breaking load of the wire rope.

The WLL shall also be determined in accordance with Appendix E.

8 TESTING OF MECHANICAL PROPERTIES Compliance of each design with the requirements of Clause 6 shall be demonstrated. NOTES: 1

The test of each design is known as the type test, which determines the adequacy of the design for achieving the required performance.

Each change in manufacturing process, grade of material, design and size necessitates separate type testing, to demonstrate compliance with the requirements of Clause 6.

In addition to type testing, effective quality control necessitates systematic testing of each lot or batch to ensure continuing compliance with the requirements of Clause 6.

Means for demonstrating compliance with this Standard are given in Appendix I.

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AS 2089—2008 9 PROOF TESTING 9.1 Proof loading Except for any roller bearings and any ball bearings, which may be removed from the sheave block during proof testing (see Clause 9.2), each sheave block shall be subjected to a proof force that is not less than the minimum proof test force specified in Table 6 applied under the conditions specified in Appendix H. TABLE 6 MINIMUM PROOF FORCES Sheave block WLL

Minimum proof test force

tonnes

kilonewtons

<20 ≥20 ≤40 >40

(2 × WLL) × 9.81 (WLL + 20) × 9.81 (1.5 × WLL) ×9.81

WLL = working load limit, in tonnes

9.2 Requirements

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Where the sheave block head fitting incorporates a roller bearing or a ball bearing, the swivel member shall first be tested in accordance with AS 2318 (which requires a test load of 1.25 times WLL). Any bearing should then be removed or protected from damage, to enable the proof test to be undertaken. Sheave blocks (with or without any roller or ball bearings removed or protected from damage) shall— (a)

withstand the application of the proof force, without sustaining damage that may affect the intended function and required degree of safety; and

(b)

after testing, be free from any deleterious permanent set or defects visible to the unaided eye.

A competent person (see Clause 3.1) shall be satisfied that the above requirements have been complied with. 9.3 Test certificate The proof testing shall be recorded on a test certificate, which shall bear the following information: (a)

Description.

(b)

Surface finish.

(c)

Proof force.

(d)

Date of proof test.

(e)

Number tested.

(f)

Identification marking correlating with the sheave blocks.

(g)

A declaration that the sheave blocks comply with this Standard (i.e., AS 2089).

(h)

The name and address of the manufacturer or supplier.

(i)

The name and address of the testing establishment.

(j)

The name of the signatory.

(k)

Type of certificate (e.g., NATA, certifying authority, supplier).

NOTE: The testing establishment should retain the original test certificate for not less than 10 years.

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AS 2089—2008

APPENDIX F

DESIGN OF SHEAVES (Normative) Clause 5.6.3 specifies requirements for rope grooves. Table F1 provides sizes of sheaves for M1 and M3 classifications. The shape of rope grooves is shown in Figure F1. The minimum sheave diameters for different types of rope are given in Table F2. This Standard covers sheave blocks for general purpose use, as defined by an M3 group classification of crane mechanisms as specified in AS 1418.1. In specific applications, design factors of sheave blocks defined herein could differ and be in accordance with AS 1418.1 for specific use. In such circumstances, the requirements of AS 1418.1 apply. TABLE F1

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SIZES OF SHEAVES FOR M1 AND M3 GROUP CLASSIFICATIONS OF CRANE MECHANISMS Maximum rope diameter (mm)

Preferred sizes of the outside diameter of sheaves (mm)

Hand operated wire rope

M1 classification

M3 classification

63 75 100

5 6 8

— — —

10 12 16

125 150 180

10 12 14

— 11 13

— 8 10

20 24 —

200 230 250

16 18 20

14 16 18

12 13 14

— — —

300 350 400

24 — —

22 26 28

16 20 22

— — —

450 500 600

— — —

32 36 44

26 28 32

— — —

Power operated wire rope

Natural fibre rope and synthe tic filament rope (mm)

Bullivants | Page 254 of 692

AS 2317.1:2018

Australian

STANDARD Lifting points Part 1: Collared eyebolts and collared eyenuts-Grade 4

STAN0ARDS I

4u,;1T1111 1 -

255 of 597 692 Bullivants | Page 247

AS 2317.1:2018

(e)

Any other finishes such as painting, oiling, diffusion processes or powder coating.

2.4

Mechanical properties

2.4.1

General

Eyebolts and eyenuts shall have sufficient strength to support the working load limit under conditions of use as set out in SeL·tjon 4. 2.4.2 Axial strength Eyebolts and studded eyenuts with a metric threaded end shall be capable of supporting the relevant strength test force specified in Table 2,2 under the relevant requirements specified in AppendixG. Eyebolts and eyenuts with a non-metric threaded end shall be capable of supporting a force equal to the strength test force specified in Table2.2, for the metric nominal size with the nearest equivalent stress area as that of the non-metric threaded end. 2.4.3

Transverse strength

Eye bolts and eyenuts shall be capable of supporting a force of 25 % of that specified for axial strength in Clause 2 4.1, under the relevant requirements specified in AppendixG. ,:, QJ

Table 2.2 - Working load limit and test forces

c ·g_

WLLTR (Transverse)

C: QJ

,:, Ql QJ

c �"'

::, Ol

Nominal size

Test force kN

Axial proof test (see Note 1)

Axial destruction test (see Note 2)

Transverse destruction test (see Note 3) 3.7

MlO

0.06

5.0

14.8

>, u C:

M12

0.10

7.9

23.6

5.9

M16

0.20

15.7

47.1

11.8

M20

0.40

31.4

94.2

23.6

M22

0.50

39.3

118

29.5

M24

0.62

49.1

148

36.8

::, u

::, u 0

M30

1.00

78.5

236

58.9

98.1

295

73.6

371

92.8

M33

1.25

,-...

M36

1.57

124

C: 0

M39

1.75

138

413

104

471

118

u QJ 0 0

� § �"'

>, .0 ,:, QJ

"'"'

M42

2.0

157

M48

2.5

197

589

148

M56

3.7

295

883

221

M64

5.0

393

1180

295

M72

6.2

1480

368

M76

7.5

491 589

1770

442

NOTE 1: Production axial proof test force, in kilonewtons = 2 x 9.81 x (WLL, i n tonnes), rounded up to three significant figures, or to one decimal place where less than 10 kN. NOTE 2: Minimum axial destructive test force, in kilonewtons = 6 x 9.81 x (WLl., in tonnes), rounded up to three significant figures. NOTE 3: Minimum transverse destructive test force= 25 % of that for axial loading.

QJ u

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AS 2318—2006

Australian Standard™ Swivels for lifting applications

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AS 2318—2006 9 PROOF TESTING (Proof Testing involves both tests) 9.1 Proof force

TEST 1 > Each swivel shall first be subjected to a proof force that is not less than (1.25 × 9.81 × (WLL in tonnes, see Appendix D)) kN applied under the conditions specified in Appendix E. Any bearing that could be subject to damage shall then be removed or protected from damage, to enable the additional proof test to be undertaken.

TEST 2 > Swivels shall then be subjected to a minimum proof force as specified in Table 1 applied under the conditions specified in Appendix E. TABLE 1 MINIMUM PROOF FORCES

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WLL, tonnes

Minimum proof force, kilonewtons

< 20

(2 × WLL) × 9.81

≥ 20 < 40

(WLL + 20) × 9.81

≥ 40

(1.5 × WLL × 9.81

9.2 Requirements The swivel shall— (a)

withstand the application of the proof force, without sustaining damage that may affect its intended function or safety;

(b)

after testing, meet the permanent set requirements of Clause 7.3.

(c)

after testing and re-assembly be able to rotate, in accordance with Clause 7.4.

A competent person (see Clause 3.1) shall be satisfied that these requirements have been complied with. 9.3 Test certificate The proof testing shall be recorded on a test certificate, which shall bear the following information: (a)

Description.

(b)

Surface finish.

(c)

Working load limit.

(d)

Proof force(s).

(e)

Date of proof test.

(f)

Number tested.

(g)

Identification marking correlating with the swivels.

(h)

A declaration that the swivels comply with this Standard.

(i)

The name and address of the manufacturer or supplier.

(j)

The name and address of the testing establishment.

(k)

The name of the signatory.

(l)

Type of certificate (e.g., NATA, certifying authority, supplier). NOTE:The manufacturer or supplier should retain the original test certificate for not less than 10 years.

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AS 2318—2006 10 MARKING 10.1 General Where a swivel is an integral part of a block or other lifting appliance, specific marking on the swivel is not required but any marking shall be such that it will not be likely to cause an incorrect interpretation of the WLL of the block or lifting appliance. Where a swivel is not an integral part of a lifting appliance, the swivel body shall be permanently and legibly marked with the information required by Clause 10.2. Any marking shall be either raised or indented. Where the marking is indented, the marks shall not have sharp edges, and the depth and location of the marks shall not impair the mechanical properties or damage any surface finish of the swivel. 10.2 Information Where required by Clause 10.1, the following information shall be marked: (a)

Manufacturer’s identification.

(b)

Working load limit.

(c)

Identification marking to correlate the swivel to the test certificate.

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11 CARE AND USE The care and use of swivels for lifting applications shall be in accordance with Appendix C.

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AS 2319—2001 Reconfirmed 2014

Australian Standard™ Rigging screws and turnbuckles

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AS 2319—2001

8 TESTING OF MECHANICAL PROPERTIES Compliance of each design with the requirement of Clause 6 shall be demonstrated. The test of each design is known as the type test, which determines the adequacy of the design for achieving the required performance. The test forces for destructive tests used for type testing, for commonly used sizes, are given in Table 3. Each change in manufacturing process, grade of material, design and size necessitates separate type testing, to demonstrate compliance with the requirements of Clause 6. NOTE: Means for demonstrating compliance with this Standard are given in Appendix E.

The compliance of each batch shall be demonstrated by either— (a)

demonstrating compliance with Clause 6; or

(b)

testing each component for hardness, to confirm it complies with the manufacturer’s specification.

9 MANUFACTURING PROOF TESTING AND QUALITY CONTROL

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9.1 Proof loading Each rigging screw and each turnbuckle shall be subjected to a force that is not less than [2 × 9.81 × (WLL in tonnes)] kN applied under the conditions specified in Appendix D. The test forces for production proof tests used for proof loading, for commonly used sizes, are given in Table 3. 9.2 Requirements The rigging screw or turnbuckle shall— (a)

withstand the application of the test force, without sustaining any damage that may detrimentally affect its intended function or safety; and

(b)

after proof loading, be free from any deleterious permanent set or defects that can be detected by visual inspection, and screwed shanks shall turn freely by hand.

9.3 Mechanical properties The compliance of each batch with the requirements for mechanical properties shall be demonstrated by either— (a)

demonstrating compliance with Clause 6; or

(b)

testing each component for hardness, to confirm it complies with the manufacturer’s specification.

9.4 Test certificate The testing of each rigging screw and each turnbuckle shall be recorded on a test certificate, which shall bear the following information: (a)

Description.

(b)

Types of end fittings.

(c)

Nominal size.

(d)

Quality grade.

(e)

Surface finish.

(f)

WLL in tonnes.

(g)

Proof force.

(h)

Date of proof test.

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AS 2321:2014

Short-link chain for lifting purposes

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AS 2321—2014

PREFACE This Standard was prepared by the Standards Australia Committee ME-025, Lifting Tackle, to supersede AS 2321—2006. The objective of all lifting tackle standards is to provide manufacturers, users, regulatory and accrediting authorities and importers with a basis for identifying products which are safe and fit for their purpose. AS 2321 is a Standard for Grade L(3), Grade P(5), Grade T(8) and Grade V(10) short link chains for lifting purposes. NOTE: Each chain grade is referred to by a letter or one of three numbers shown below: (a)

L, 3, 30 or 300.

(b)

P, 5, 50 or 500.

(c)

T, 8, 80 or 800.

(d)

V, 10, 100 or 1000.

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This edition includes the following changes from the previous edition: (a)

Revision to link tolerances.

(b)

Revision to chain marking.

(c)

Addition of Grade V(10, 100, 1000).

(d)

Provision for a bend test.

(e)

Delete Grades M and S.

(f)

Clarification of elongation requirements.

(g)

Specification of impact testing for specific Grade V materials.

(h)

Cognisance of ISO 3076, Round steel short link chains for general lifting purposes— Medium tolerance slings for chain slings—Grade 8.

(i)

Includes the basis for calculation of dimensions and tolerances of Grade T chain.

(j)

Includes the basis for working load limit and test requirements for Grades T and V chain.

Statements expressed in mandatory terms in notes to tables are deemed to be requirements of this Standard. The terms ‘normative’ and ‘informative’ have been used in this Standard to define the application of the appendix to which they apply. A ‘normative’ appendix is an integral part of a Standard, whereas an ‘informative’ appendix is only for information and guidance.

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AS 2321—2014 4 DEFINITIONS For the purpose of this Standard, the definitions below apply. 4.1 Barrel The straight side of a link, which may include the weld zone adjoining the curved ends. 4.2 Bend test A test applied to a self-colour sample of chain to assist in the verification of the integrity of the weld. (Refer to Appendix G and Clause 9.3.) 4.3 Breaking force The maximum force that a test sample of a chain withstands during a destruction test. NOTE: Minimum forces that test samples of a chain are required to withstand are detailed in Tables E1 and E2.

4.4 Competent person A person who has, through a combination of training, education and experience, acquired knowledge and skills enabling that person to correctly perform a specific task. NOTE: Requirements for competent persons are specified in Clause 5.

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4.5 Design factor The numerical value, generally expressed as a ratio, to express the relationship of the minimum breaking force, in kilonewtons, to the working load limit (WLL), in tonnes, of the chain. NOTE: Design factor =

Minimum breaking force . (9.81 × WLL)

4.6 Finished condition The condition of chain after completion of all processing. 4.7 Gauge length The portion of the tensile test sample containing the number of links for the purpose of undertaking a specified destructive test. 4.8 Mean diameter (d m) The mean of two measurements, at right angles to each other, of a section (of the material of a chain link) clear of the weld. 4.9 Nominal stress Force divided by two times the cross sectional area of the straight section of the link. Refer to Appendix E, Table E2, Note 4, for an example. 4.10 Nominal chain size (d) The designated size of a chain. 4.11 Nominal material size (dn) The nominal diameter of the material from which a chain is made. 4.12 Non-calibrated chain Chain manufactured to specified link dimensions, tolerances and mechanical properties, but not to a dimensional accuracy, over a series of links (which would be required where the chain is to operate on a sprocket or a pocketed or toothed wheel).

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AS 2321—2014 4.13 Processing Any treatment of a chain subsequent to welding including heat treatment, proof-testing and protective coating. 4.14 Proof force The minimum force to which the whole of a chain is subjected to (refer to Clause 9.1 and Tables E1 and E2 of Appendix E). 4.15 Self-colour A surface finish arising from the essential manufacturing operations, usually being a closely adhering oxide film due to the heat treatment and subsequent handling. 4.16 Shall Indicates that a statement is mandatory. 4.17 Should Indicates a recommendation.

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4.18 Tensile test sample A length of chain that is representative of the lot from which it has been taken and containing the gauge length and any adjoining links that may be necessary to engage with the jaws of the tensile testing machine. 4.19 Total elongation The elongation at the point of fracture of a chain expressed as a percentage of the gauge length, and comprising plastic elongation and elastic elongation. (See Appendix F.) 4.20 Type test The test to validate any new design changes in specification, to material chemistry, to material supplier and/or to process. 4.21 Working load limit (WLL) The maximum load that is permitted to be applied to the chain. NOTE: The WLL may be derated for particular conditions of use.

5 COMPETENT PERSONS REQUIREMENTS 5.1 General Competent persons shall be suitably trained, qualified by knowledge and practical experience, and with the necessary instruction to enable assessments of short link chain for lifting purposes to be carried out. They shall be able to detect and evaluate defects and weaknesses that may affect the intended performance of the equipment. 5.2 Competency standards and procedures Competency standards and procedures relating to the role and duties of competent persons shall include the requirements of this Standard. They shall incorporate an established competencybased training course. Documentation of competency standards and procedures shall be maintained.

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AS 2321—2014 5.3 Visual acuity The competent person shall have satisfactory near and medium range vision. The visual acuity of a competent person shall be tested periodically, with a maximum duration of 2 years between each test, by an optometrist or suitably trained person. The competent person shall be able to demonstrate clear near vision. Near vision acuity (Jaeger No. 1) shall permit reading a minimum of Times Roman 4.5 points vertical height at not less than 300 mm with one or both eyes, either corrected or uncorrected. NOTE: AS 3978 gives guidance on visual acuity for visual inspections.

6 DIMENSIONS 6.1 General The chain shall comprise links that conform to one of the nominal sizes, dimensions and tolerances specified in Clauses 6.2 and 6.3. 6.2 Grades L, P and T Figure 1 illustrates Type 1 (smooth welds) and Type 2 (asymmetric welds) of Grades L, P and T chain links.

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Table 1 sets out the dimensions (including tolerances) of Grades L, P and T chain links.

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AS 2321—2014

e e dw

p (a) Type 1 (Smooth welds) e e

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w 3 w1

p (b) ) Type 2 ( Asymmetric welds) LEGEND: p pitch ( internal l ink length) d n measured diameter of the material, except at the weld d w measured diameter of the material at the weld (type 1) or weld dimension perpendicular to the plane of the l ink (type 2) G dimension in other planes (type 2) e length affected by welding, on either side of the centre of the l ink w1 internal l ink width away from the weld (type 2) w 3 external l ink width over the weld (types 1 and 2) w4 internal l ink width at the weld (type 1)

FIGURE 1 CHAIN LINK—DIMENSIONS (GRADES L, P AND T)

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AS 2321—2014 TABLE 1 DIMENSIONS OF LINKS (GRADES L, P and T) (Refer to Figure 1) millimetres 1

Nominal size

Pitch (internal link length) Diameter tolerance

Tolerance

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Width

Weld diameter

Internal

External

Internal

Type 2

Types 1 and 2

Type 1

Types 1 and 2

Type 2

w1 min.

w3 max.

w4 min.

dw max.

G max.

4 6 7

+0.08/−0.24 +0.12/−0.36 +0.14/−0.42

12 18 21

±0.4 ±0.5 ±0.6

5.0 7.5 8.8

14.8 22.2 25.9

5.2 7.8 9.1

4.4 6.6 7.7

5.0 7.5 8.8

8 10 13

+0.16/−0.48 +0.20/−0.60 +0.26/−0.78

24 30 39

±0.7 ±0.9 ±1.2

10.0 12.5 16.3

29.6 37.0 48.1

10.4 13.0 16.9

8.8 11.0 14.3

10.0 12.5 16.3

16 18 19

+0.32/−0.96 ±0.9 ±0.95

48 54 57

±1.4 ±1.6 ±1.7

20.0 22.5 23.8

59.2 66.6 70.3

20.8 23.4 24.7

17.6 19.8 20.9

20.0 22.5 23.8

20 22 26

±1.0 ±1.1 ±1.3

60 66 78

±1.8 ±2.0 ±2.3

25.0 27.5 32.5

74.0 81.4 96.2

26.0 28.6 33.8

22.0 24.2 28.6

25.0 27.5 32.5

28 32 36

±1.4 ±1.6 ±1.8

84 96 108

±2.5 ±2.9 ±3.2

35.0 40.0 45.0

104.0 118.0 133.0

36.4 41.6 46.8

30.8 35.2 39.6

35.0 40.0 45.0

40 45

±2.0 ±2.25

120 135

±3.6 ±4.1

50.0 56.3

148.0 167.0

52.0 58.5

44.0 49.5

50.0 56.3

NOTE: Basis for calculation—Dimensions and tolerances: (a)

(b)

(c)

Diameter tolerance For nominal sizes less than 18 mm, the diameter of the material in the finished chain link should not differ from the nominal diameter by more than +2%, −6%, except at the weld. For nominal sizes 18 mm and greater, the diameter of the material in the finished chain link should not differ from the nominal diameter by more than ±5%, except at the weld. Pitch and tolerance The values for the nominal pitch, p are based on 3 × dn. The calculated values are rounded to 1 mm. The pitch tolerances are based on ±3%. The calculated values are rounded to 0.1 mm. Width The values for the internal width of Type 2 w1 are based on 1.25 × dn. The calculated values are rounded to 0.1 mm. The values for the external width of Types 1 and 2 w3 are based on 3.7 × dn. The calculated values of <100 mm are round to 0.1 mm. The calculated values of ≥100 mm are rounded to 1 mm. The values for the internal width of Type 1 w4 are based on 1.3 × dn. The calculated values are rounded to 0.1 mm.

(d)

Weld diameter The values for the weld diameter of Type 1 or for the weld diameter perpendicular to the plane of the link of Type 2 dw are based on 1.1 × dn. The calculated values are rounded to 0.1 mm. The value for the dimension in other planes of Type 2 G are based on 1.25 × dn. The calculated values are rounded to 0.1 mm.

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AS 2321—2014 6.3 Grade V Figure 2 illustrates the dimensions required for Grade V chain links. Table 2 sets out the dimensions of Grade V chain links in V 200 category. Table 3 sets out the dimensions of Grade V chain links in V 400 category.

w1 w3

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LEGEND: p = pitch ( internal l ink length) w1 = internal l ink width away from weld w 3 = external l ink width over the weld d n = measured diameter of the material, except at the weld

FIGURE 2 CHAIN LINK—DIMENSIONS (GRADE V)

TABLE 2 GRADE V(100) DIMENSION CHART—V 200 INFORMATION (Refer to Figure 2) millimetres Pitch (internal length, maximum)

Minimum

Maximum

5 6 7

15.5 18.5 22.9

6.5 7.8 9.1

7.5 9.0 10.9

8 10 13

26.4 32.0 41.6

10.4 13.0 16.9

12.7 15.2 19.5

16 20 22

51.2 64.0 70.4

20.8 26.0 28.6

24.0 30.0 33.0

26 32

80.3 98.9

33.8 41.6

39.0 48.0

Internal width

NOTE: Tolerance for dn—refer to manufacturer’s specifications.

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AS 2321—2014 TABLE 3 GRADE V(100) DIMENSION CHART—V 400 INFORMATION (Refer to Figure 2) millimetres

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Pitch (internal link length)

Internal width (minimum)

External width (maximum)

Tolerance

4 5 6

12 15 18

±0.4 ±0.5 ±0.5

5.2 6.5 7.8

14.8 18.5 22.2

7 8 10

21 24 30

±0.6 ±0.7 ±0.9

9.1 10.4 13.0

25.9 29.6 37.0

13 16 18

39 48 54

±1.2 ±1.4 ±1.6

16.9 20.8 23.4

48.1 59.2 66.6

19 20 22

57 60 66

±1.7 ±1.8 ±2.0

24.7 26.0 28.6

70.3 74.0 81.4

23 26 28 32

69 78 84 96

±2.1 ±2.3 ±2.5 ±2.9

29.9 33.8 36.4 41.6

85.1 96.2 104.0 115

NOTE: Tolerance for dn—refer to manufacturer’s specifications.

7 MATERIAL 7.1 General The steel used in chain manufacture shall be such that, after suitable heat treatment and in its finished condition, the chain complies with the mechanical properties specified in this Standard for the chain grade. 7.2 Requirements of steel Chain shall be manufactured from a hot-rolled material that is specified in Tables 4 and 5, from wire drawn from such a material, or from material processed to meet the intent of this Standard. 7.3 Deoxidation The steel shall be fully killed and shall be made in conformity with a suitable deoxidation process in order to obtain an austenitic grain size of 6 or finer when tested in accordance with AS 1733. The steel shall be stabilized to ensure that the manufactured chain, when suitably heat-treated, is protected against strain-age embrittlement in service. 7.4 Weldability The steel shall be of reliable weldable quality. 7.5 Traceability The steel shall be suitably identified to ensure that the steel manufacturer, steel heat number and rolling number can be all traced.

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AS 2321—2014 TABLE 4 MATERIAL AND HEAT TREATMENT 1

Requirements of steel

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Grade of chain [see Clause 10.2(b)]

Special requirements Type of steel

Steel specification

Fully killed, fine-grained

Product check analysis, percent

Heat treatment

Phosphorus max.

Sulfur max.

Carbon max.

AS 1442

0.050

0.30

Stress relieve or normalize

Fully killed, fine-grained

AS 1442 AS 1444

0.045

0.050

0.30

Harden and temper

Fully killed, fine-grained

AS 1444

0.030

0.30

Harden and temper

V 200

Fully killed, fine-grained

AS 1444

0.025

0.35

Harden and temper

V 400

Fully killed, fine-grained

AS 1444

0.020

0.35

Harden and temper

NOTES: 1

To ensure the chain is stabilized against strain-age embrittlement during service, the steel typically contains at least 0.025% aluminium, but not more than 0.05% aluminium.

Materials other than those specified in AS 1442 or AS 1444 are not precluded, provided they meet the intent of this Standard.

7.6 Grade T(80) requirements The specified nominal stress at breaking force of this grade is 800 MPa. 7.7 Grade V(100) requirements The specified nominal stress at breaking force of this grade is 1000 MPa. Grade V(100) chain can be produced by using materials that are suitable for 200°C or 380°C operating ranges. Each temperature range has specific minimum alloying elements requirements. V 200 refers to Grade V(100) chain that has a maximum operating temperature of 200°C, V 400 refers to Grade V(100) chain that has a maximum operating temperature of 380°C. TABLE 5 GRADE V(100) MATERIALS Grade

Nickel, min. percent

Chromium, min. percent

Molybdenum, min. percent

V 200

0.40

0.15

V 400

0.70

0.50

0.30

7.8 Toughness type test The manufacturers shall be able to demonstrate by type test that the material specification used for Grade T and V chains, in its heat treated condition, has been tested in accordance with AS 1544.2, Charpy impact test. No individual value may be below 28 J when tested at −20°C, or at a lower temperature if specified. NOTE: If the chain links are too small to extract a suitably sized specimen in accordance with AS 1544.2, the impact test requirements of ISO 3076 may be used as substitute.

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AS 2321—2014 Alternative Grade V(100) materials can be used provided— (a)

the type test requirements, all mechanical properties as well as the impact test requirements of this standard are fully complied with; and

(b)

a comparative risk assessment in using the specified material and the alternative material has been completed, which analyses both the interaction of the material with the chain manufacturing process as well as the application of the finished chain during use and no additional risks are identified.

7.9 Chain operating at low temperatures Where the chain is to be used at temperatures colder than −10°C, the user shall seek advice from the manufacturer. 8 MANUFACTURE 8.1 Welding

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Chain shall be manufactured by welding and finished to the required dimensions, as specified in Figures 1 and 2, and Tables 1, 2 and 3. The links and welds shall not show fissures, notches or similar faults that are detrimental to the chain. The thickness of the weld material shall be not less than the diameter of the material of the link. For smooth welded chain, fins caused by welding shall be removed and the weld shall be smoothly finished all round. For asymmetric welded chain, the fins caused by welding shall be removed from the outside of the link surface, leaving the projections on the inside and thus forming a smooth exterior asymmetric weld. The positioning of the weld at the centre of the straight barrel and the tolerances imposed on protrusions at the weld should provide the required clearances. 8.2 Heat treatment

8.2.1 General Chain Grades P, T and V shall be hardened from a temperature above the AC3 point, quenched and tempered prior to being tested for mechanical properties.

8.2.2 Tempering for Grade V The tempering temperature shall be at least 200°C for V200 and 380°C for V400. The tempering conditions shall be at least as effective as the tempering temperature maintained for a period of 1 hour. This requirement is the responsibility of the chain manufacturer. When proposed for verification, samples of chain shall be tested after they have been reheated to and maintained for 1 h at the tempering temperature and then cooled to room temperature. These samples shall comply with the requirements of Appendix E, F and G. NOTE: For chains with a surface finish other than natural black, samples required for verification shall be taken and reheat treated prior to the surface finishing process.

8.3 Visual examination after manufacturing proof force testing After the manufacturing proof force test (see Clause 9.1), the chain shall be inspected by a competent person, under suitable lighting and appropriate ergonomic conditions to ensure the links and welds are free from fissures, notches or similar defects that are detrimental to the chain.

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AS 2321—2014 9.4 Type testing requirements Compliance of each design with the requirements of Clause 8 shall be demonstrated by the following: (a)

For type testing, the chain shall comply with all testing requirements of Clauses 9.1, 9.2 and 9.3 above. These tests determine the adequacy of the design for achieving the required performance.

(b)

Each change in the manufacturing process, grade of material, design and size other than length necessitates separate type testing, to demonstrate compliance with the requirements of Clause 9.

(c)

Toughness type test, refer to Clause 7.8.

(d)

Records of type testing including results of verification and validation shall be kept.

9.5 Verification Effective quality control necessitates systematic testing of each lot or batch to ensure continuing compliance with the requirements of Clauses 9.1 to 9.3. 10 MARKING

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10.1 General Each length of chain shall be permanently and legibly marked at intervals of not more than 20 links or 1 m, the marking being either raised or indented. Where the marking is indented, the marks shall be without sharp edges and the depth and location of the marks shall be on the parallel barrel opposite the weld, but shall not reduce the strength of the chain. 10.2 Information The following information shall be marked: (a)

Manufacturer’s identification.

(b)

Quality grade, i.e. one of the following: (i)

L, 3, 30 or 300.

(ii)

P, 5, 50 or 500.

(iii)

T, 8, 80 or 800.

(iv)

V, 10, 100 or 1000.

11 TEST CERTIFICATE

"Manufacturers"

The testing shall be recorded on a test certificate, which shall bear the following information: (a)

Nominal size of chain.

(b)

Grade.

(c)

Surface finish.

(d)

Quantity.

(e)

Batch or lot number.

(f)

Manufacturing proof force, in kilonewtons, applied for the testing specified in Clause 8.1.

(g)

Breaking force, in kilonewtons (i.e. confirmation that the specified minimum breaking force was met or exceeded).

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AS 2321—2014 (h)

Total ultimate elongation at fracture, as a percentage (i.e. confirmation that the specified minimum total ultimate elongation that been met or exceeded).

(i)

A declaration that the chain complies with this Standard.

(j)

The name and address of the manufacturer or supplier.

(k)

The name and address of the testing establishment.

(l)

An approved signatory.

(m)

Type of certificate (e.g. NATA, certifying authority, supplier). NOTE: The manufacturer should retain the test certificate for not less than 10 years.

Any other information requested by the customer.

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(n)

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AS 2321—2014

APPENDIX B

CAUTIONS IN USE AND APPLICATIONS (Informative) B1 WORKING LOAD LIMIT (WLL) Do not use a chain in a manner that will exceed the WLL of the chain for the particular conditions of use. The WLL for each chain is based on the following design factors: (a)

For Quality Grade L ............................................................................................................ 5.

(b)

For Quality Grades P, T and V ........................................................................................... 4.

General conditions of use are equivalent to a group classification for crane mechanisms of M3 as specified in AS 1418.1. B2 HYDROGEN EMBRITTLEMENT

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Hydrogen embrittlement is a dangerous condition that should be prevented. In certain environments, such as where acid pickling or cathodic cleaning is carried out, hydrogen embrittlement can occur in steels that are quenched and tempered, because of the absorption of atomic hydrogen generated at steel surfaces. B3 CORROSIVE ENVIRONMENT A risk assessment should be undertaken where chain is used in acidic, alkaline or other corrosive environments. The manufacturer or supplier should be contacted to determine the best grade of chain for the particular application. B4 EFFECTS OF HOT ENVIRONMENTS The strength of all grades of chain is adversely affected by excessively elevated temperatures. Where the temperatures are likely to exceed 200°C, contact the manufacturer for the required reduction in working load limit. B5 LOW TEMPERATURE Where the chain is to be used at temperatures colder than –10°C, the user needs to seek advice from the manufacturer (refer to Clause 6.9). B6 HEAT TREATMENT Chain in its finished condition should never be heat-treated. B7 GALVANIZING AND OTHER METALLIC COATINGS Chains should not be hot-dip galvanized, electroplated or diffusion coated except by the manufacturer. Hot-dip galvanizing and diffusion coating can reduce the breaking load and WLL should be derated accordingly.

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AS 2321—2014 B8 PRESERVING THE CHAIN The useful life of chains is considerable and may be easily maximized by observing the following precautions: (a)

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(b)

Care: (i)

Never heat or heat-treat chain.

(ii)

Lightly oil chain prior to prolonged storage.

(iii)

Store chain in clean dry places.

(iv)

Protect from any weld spatter and arc strikes.

Use: (i)

Ensure that chain is free of any significant damage or wear.

(ii)

Ensure that chain is evenly loaded in use.

(iii)

Ensure that chain is free of twists and knots and is protected from any sharp corners when used.

(iv)

Ensure that chain is loaded gradually without shock.

(v)

Avoid crushing chain.

B9 INSPECTION It is important to regularly inspect chain, in particular, observing the following: (a)

If necessary, chain should be cleaned before it is inspected.

(b)

Every chain link should be individually inspected for any signs of wear, twisting, stretching, nicks or gouging.

(c)

Any worn links should be measured to determine the degree of wear, which should not exceed that allowed for by the manufacturer.

(d)

Chain links having any defects should be clearly marked to indicate rejection and the chain withdrawn from service.

(e)

Any damaged chain should be destroyed.

(f)

A chain inspection record should be provided for each chain.

(g)

The results of each inspection and repair should be entered on the chain inspection record.

(h)

Check markings on chain. Refer to Clause 10.

(i)

Refer to dimension charts in Tables 2 and 3.

(j)

Additional information is available in AS 3775.2.

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AS 2321—2014

APPENDIX E

TEST FORCES AND CONDITIONS FOR THEIR APPLICATION (Normative) E1 TENSILE TEST SAMPLE (a)

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(b)

A tensile test sample shall contain not less than the following number of links: Nominal size, mm

Number of links

≤6 >6 ≤17 >17

9 7 5

Gauge length shall be determined and recorded (see Clause 4.7 and Figure E1).

Engaged Link Gauge length

FIGURE E1 GAUGE LENGTH

E2 CONDITIONS The following conditions apply to the application of test forces to a chain: (a)

The testing machine shall be calibrated in accordance with AS 2193 and shall be capable of Class A results when testing mechanical properties (see Clause 8) and Class C results when proof testing (see Clause 8.1).

(b)

Except for proof-loading and any application of temporary protective coatings for storage purposes, manufacturing processes shall be completed.

(c)

A test sample shall be engaged in the tensile testing machine in a manner such that the load acts along the axis of the chain to simulate the normal operating condition without twist and without damage to the engaging links. The specified minimum proof force shall be applied. After the load has been released, the gauge length of the test sample shall be determined, as specified in Paragraph E1(b). A gradually increasing load shall then be applied until the chain achieves the minimum break strength and minimum total elongation specified in Tables E1 and E2. The elongation may be determined in accordance with Appendix F.

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AS 2321—2014 Where any test sample fails to fulfil the test requirements, two further test samples, selected from the sample lot of chain, shall be retested and corrective actions with respect to the fail sample shall be taken. The lot complies when the original tensile test or the additional retests are satisfactory. (d)

The lot shall be proof tested with a force that is not less than the relevant one specified in Tables E1 and E2, in a tensile testing machine, in such a manner that the load acts along the axis of the chain to simulate the normal operating condition, without twist and without damage to the engaging links. A greater proof force may be applied, provided it does not impair the integrity of the finished chain. TABLE E1 CHAIN SIZES, WLL AND TEST FORCES GRADE L, P AND T

Minimum test forces

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Nominal chain size, d mm

Grade L WLL

Grade P

Manufacturing Breaking proof

WLL

Grade T

Manufacturing Breaking proof

WLL

Manufacturing Breaking proof

tonnes

4 6 7

0.16 0.36 0.49

3.2 7.1 9.7

7.9 17.8 24.2

0.32 0.72 0.98

6.3 14.2 19.3

12.6 28.3 38.5

0.5 1.1 1.5

12.6 28.3 38.5

20.1 45.2 61.6

8 10 13

0.65 1 1.7

12.7 19.8 33.5

31.7 49.5 83.7

1.28 2.00 3.38

25.2 39.3 66.5

50.3 78.6 133

2 3.2 5.3

50.3 78.5 133

80.4 126 212

16 18 19

2.58 3.28 3.67

50.7 64.2 71.9

127 161 180

5.12 6.50 7.29

101 128 143

202 255 286

8 10 11.5

201 254 284

322 407 454

20 22 26

4.03 4.89 6.83

79.2 95.8 134

198 240 335

8.03 9.68 13.53

158 190 266

315 380 531

12.5 15 21.2

314 380 531

503 608 849

28 32 36

8 10.34 13.09

157 203 257

393 507 642

16.00 20.51 25.94

314 403 509

628 805 1018

25 31.5 40

616 804 1020

985 1290 1630

40 45

16.15 20.43

317 401

792 1002

32.03 40.55

629 796

1257 1591

50 63

1260 1590

2010 2540

NOTES: 1

The minimum total elongation shall be as follows: (a) For Quality Grade L chain, 20%. (b) For Quality Grade P and T chains, 17%. (c) For Quality Grade V chain, 20%.

The listed values for manufacturing proof and breaking force are rounded to values <100 kN to 0.1 kN and >100 kN to 1 kN.

Calculation for WLL and test requirements for Grades T and V— (a) calculation for WLL, in tonnes— 1 NS × d n2 2× ×π× WLL = 4 4 g × 1000 where NS = nominal stress at minimum breaking force for grades T and V only

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AS 2321—2014

(b) calculation for manufacturing proof force, in kN— 1 NS 2 2 ×dn × ×π× 1.6 4 MPF = 1000 (c) calculation for breaking force, in kN— 1 2 2 BFmin = 4

× π × NS × d n 1000

The nominal stress in the chain at minimum breaking force shall be as follows: (a) For Quality Grade L chain, 315 MPa. (b) For Quality Grade P chain, 500 MPa. (c) For Quality Grade T chain, 800 MPa. (d) For Quality Grade V chain, 1000 MPa. Example of calculation of nominal stress, using 10 mm Grade V(1000) as an example—

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157 kN 1000 MPa = ⎛ 102 × π ⎞ ⎜ ⎜ ⎝

× ⎟2 ⎟ ⎠

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AS 2321—2014 TABLE E2 CHAIN SIZES, WLL AND TEST FORCES GRADE V(100) WLL tonnes

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Chain size mm

Minimum test forces kN

Single-leg

Manufacturing proof

Breaking

4 5 6

0.63 1.0 1.4

15.7 24.5 35.3

25.1 39.3 56.5

7 8 10

1.9 2.5 4.0

48.1 62.8 98.1

77.0 101 157

13 16 18

6.7 10 12.5

166 251 318

265 402 509

19 20 22

14 16 19

354 393 475

567 628 760

23 26 28 32

21 26.5 31.5 40

519 664 770 1005

831 1060 1230 1610

NOTES: 1 The minimum total elongation shall be as follows: (a) For Quality Grades L chain, 20%. (b) For Quality Grades P and T chains, 17%. (c) For Quality Grades V chain, 20%. 2 The WLLs of Grade V(100) chain in the table above is based on nominal dimensions. Some manufacturers may have higher WLLs. 3 The listed values for manufacturing proof and breaking force are rounded to values <100 kN to 0.1 kN and >100 kN to 1 kN. 4 Calculation for WLL and test requirements for Grades T and V— (a) calculation for WLL, in tonnes— 1 NS × d n2 2× ×π× WLL = 4 4 g × 1000 where NS = nominal stress at minimum breaking force for grades T and V only (b) calculation for manufacturing proof force, in kN— 1 NS 2 2 ×dn × ×π× 1.6 4 MPF = 1000 (c) calculation for breaking force, in kN— 1 2 2 BFmin = 5

× π × NS × d n 1000

AS 2321—2014

APPENDIX F

DETERMINATION OF ELONGATION (Normative) F1 DETERMINATION OF PLASTIC ELONGATION OF BROKEN TEST SAMPLE The total elongation (plastic plus elastic) of chain always exceeds the plastic elongation by the elastic elongation. Where the plastic elongation alone is measured and found to be no less than that specified in Note 1 of Table E2, Appendix E, then the chain is to be regarded as complying with this Standard. The procedure is to determine the total pitch of the gauge length in accordance with Paragraph E2(c), Appendix E. The test sample is to be loaded gradually and smoothly until breakage occurs as shown in Figure F1.

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The plastic elongation, expressed as a percentage, is determined as follows: Plastic elongation (%) = where N

⎡⎢⎛ N ( A + B) ⎞ ⎤ ⎜GL ( N − 1)⎟ − 1⎥ ×100 ⎠ ⎦ ⎣⎝

= number of links in the test sample (Figure F1 below depicts 9 links, 7 of which comprise the test sample)

GL = gauge length, see Paragraph E2(c), Appendix E The maximum load obtained during this procedure is the actual breaking load.

FIGURE F1 DETERMINATION OF PLASTIC ELONGATION

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AS 2321—2014 F2 DETERMINATION OF TOTAL ELONGATION OF UNBROKEN TEST SAMPLE The procedure is to determine the total pitch of the gauge length in accordance with Paragraph E2(c) Appendix E, and, with the tension maintained between 8% and 12% of the specified minimum proof load, to mark the position of the moving head. The load is then increased, gradually and smoothly, until the head has moved the required minimum total elongation, this movement being— Specified minimum total elongation (%) × 0.01 × GL (see Paragraph F1) If the specified minimum breaking load has not been reached when the elongation achieves the specified minimum, then the loading is to be continued until the specified minimum breaking load is attained. NOTE: This procedure presumes no significant elastic strain between the points of engagement of the sample and the movement indicator. Where such strain is significant, it is to be determined and appropriate allowance made.

F3 DETERMINATION OF TOTAL ULTIMATE ELONGATION The determination of total elongation using autographic instrumentation produces a load/extension diagram similar to Figure F2.

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NOTE: Where the recorded extension is that of the moving head, appropriate allowances are to be made for the elastic strain of the test sample holding system where such strains are found to be significant.

The elongation is based on the total elongation at fracture (E) shown in Figure F2. This is then expressed as a percentage of the gauge length (see Paragraph E2(c), Appendix E) of the sample where— ⎛ Total elongation (E) ⎞ ⎟ ×100 Elongation (%) = ⎜ ⎝ Gauge length (GL) ⎠ Breaking Force (BF) Specified Minimum Breaking Force (BFmin)

Manufacturing Proof Force (MPF)

Working Load Limit (WLL)

Total elongation at fracture (E)

FIGURE F2 TYPICAL LOAD/EXTENSION DIAGRAM

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Manufacturers Identifications

CHAIN MANUFACTURERS

MARKINGS

BRADLINK

Western Australia

KUPLEX

T 80, KX8, KX10

United Kingdom

SERAFINI

Queensland

Su and KITO on opposite ends of link

Japan

KITO FRAMM COLUMBUS McKINNON (NOW PWB ANCHOR)

T cm & HA Alternatively...am &A

Norway America

PWB ANCHOR

HA 800 - PWB

Australia

GUNNEBO GT8

First Figure is chain size in mm, 8 is the grade (80) "13-8-(G-R)"

Sweden

PWB L

Australia

PWB P

Australia

RUD

Germany

Bullivants | Page 308 of 692

Manufacturer* Actek Manufacturing & Engineering American Drill Brushing Company

Armstrong Co.

Typical Device

Markingsǂ

Swivel hoist rings

ACTEK

Brewer-Titchener Shackles Corp.1 Campbell Chain Company1 (formerly California Chain) Chicago Hardware and Fixture Co. Columbus McKinnon/Midlan d Forge2

Shackles, links Turnbuckles, eyebolts, shackles

(This icon is sometimes difficult to see clearly, even on new ones.) BTC Campbell, CCA, C , CC,

Chicago, CHF

Shackles, hooks

Dekalb Forge Co.3

Eyebolts, shackles

www.armstrong.com (WRONG)

www.cooperhandtools.com http.//www.cooperhandtools.com/br ands/campbell/index/cfm

www.chicagohardware.com www.cmworks.com

Shackles, hooks

The Crosby Group

www.actekmfg.com http://www.mechanicalsupplies.cc/i d6.html

Rings, bolts

Eyebolts

Website

Crosby, CL, CrosbyLaughlin, CG CROSBY (all capital letters) DFC,

www.thecrosbygroup.com www.dekalbforge.com www.rockforddropforge.com

Rockford Drop Forge Edward W. Daniel Co.4

Eyebolts, shackles

GunneboJohnson

Shackles, chains, master links

Halfen-Deha

Pin lifting system for pre-cast concrete

Jergens

Hoist rings

www.ewdaniel.com Gunnebo, G-R, (GunneboRamnas), Johnson DEHA JERGENS Jergens

www.gunnebojohnson.com

HALFEN_DEHA www.jergensinc.com

Bullivants | Page 309 of 692

Ken Forgin Inc./Cleveland City Forge4 Letellier Material Handling Equipment Inc.

Eyebolts, turnbuckles

K, CCF, KF

www.kenforging.com

Shackles, the below-the-hook lifting devices

LMHE, LETELLIER

www.lmhe.com

Pewag

Chain hooks, master links, including stainless steel products

The Skookum Co., Inc/Ulven Forging Co.5

Shackles, pear/master links

Suncor Stainless Yoke Industrial Corporation

Stainless steel shackles, chain, hooks, etc Hooks, master links, chain slings, shackles

(all lower case; dots above 'g' may or may not be present) SKOOKUM

Suncor YOKE (all capital letters)

www.pewagchain.com

www.ulvencompanies.com www.suncorctainless.com http.//www.yoke.net/

NOTES: Manufacturer*- Matching superscript numbers identify companies that may have a close affiliation with one another. Markingsǂ - Fonts used to identify manufacturer marks (e.g. K, G-R, CCF) may not represent the exact font used on the hardware. Markings denoting a country of origin are not considered appropriate manufacturer marks. This is a list of country markings currently identified: Equipment material with the following markings may indicate S/CI parts:  China  Holland  Korea  USA  Germany  Japan  Taiwan

Bullivants | Page 310 of 692

CHAIN MARK

CHAIN MAKER

CHAIN MAKERS MARK

RUD

VIP.8S RAISED H8 or T

THIELE

SCHILETER

H15

KUPLEX

8 KUPLEX 10 KX-8 KX-10

H16

PEWAG

PEWAG AUSTRIA PWOA NICROMAN

H23

KITO

H26

CROSBY

H29

KWB

SUPERALLOY AUSTRIA

H30

A.S KjaettingFabriken

FRAM NORWAY POLAR BEAR

H32

GUNNEBO

8G RAMNAS GO SWEDEN

H37

WEISSENFELS

W8 ITALY.

H39

ELEPHANT

H46

McKINNON

H91

YOKE

H94

EXCEL

GK2. 10-8.

H95

GEMLA

H98

PWB

HA800 PWB G800

BRADLINK

T8-T GERMANY INDENTED T8-T IC8.B8A.8 LO2 S10 446 004 044 G

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MARKINGS

GRADE

MANUFACTURER

COUNTRY OF MANUFACTURE

RUD

VEST TYSKLAND

J.D.THEILE

VEST TYSKLAND

AUGUST THIELE

VEST TYSKLAND

BECKER-PRUNTE

VEST TYSKLAND

ERLAU

VEST TYSKLAND

W. SCHULTE

VEST TYSKLAND

MEILI & CO

SVEITS

KUPLEX

FRANCE

PENGG-WALENTA (PEWAG)

ØSTRIKE

RAMNES

SVERIGE

SCULTE & CO

VEST TYSKLAND

CAMBELL

USA

KITO

JAPAN

ROTTGERS

VEST TYSKLAND

CROSBY

USA

ORSA

SVERIGE

DUISBURGER

VEST TYSKLAND

BRUCKL

ØSTRIKE

KJETTINGFABRIKKEN

NORGE

SCHNEIDER

VEST TYSKLAND

GUNNEBO

SVERIGE

WALDER

VEST TYSKLAND

UNNA

VEST TYSKLAND

NICH

JAPAN

KYOKUTO

JAPAN

WEISSENFELS

ITALIA

EWEPHANT

JAPAN

SCHOTTLER

VEST TYSKLAND

FORCE FRANCE

VEST TYSKLAND

SCHOTTER

VEST TYSKLAND

GRADE 80 CHAIN NO5 AND MARKINGS GUNNEBO H/32

Bullivants | Page 312 of 692

AS 2359.1:2019

Powered industrial trucks Part 1: General requirements

Originated as part of AS B270—1968. Previous edition AS 2359.1—1995. Fourth edition 2015. Fifth edition 2019.

COPYRIGHT © Standards Australia Limited 2019 All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher, unless otherwise permitted under the Copyright Act 1968 (Cth).

Bullivants | Page 313 of 692

Copyrighted material licensed to SAI Global^Wesfarmers Industrial & Safety. Further reproduction, distribution, storage or use on a network is prohibited. Printed / viewed by: [ben.hogan@bullivants.com] @ 2019-12-09 15

Section 6

AS 2359.1:2019

Fork arms and attachments

Fork arms shall be in accordance with requirements of AS 2359.14—2005 Clause 6.1.

that attachment, the actual capacity of the truck shall be derated. The load centre distances of the attachment shall be taken into account.

The attachment shall be in accordance with at least one of the following: (a) The attachment shall be designed to withstand, at the designated load centre distance, a static (b) The attachment shall be designed in accordance with AS 3990 or equivalent technical Standard where applicable. The design shall take into account all dynamic loads and forces and, based on the intended life of the equipment, include a fatigue stress analysis of known critical stress-raising areas such as cutouts and base material next to welds. (c)

The attachment shall be designed to withstand dynamic endurance testing under effective loads practicable for large quantity manufacture only, due to the prohibitive costs involved.)

(f) markings conforming with AS 2359.5.

Each attachment shall be fully tested prior to shipment to ensure correct operation. The tests shall include —

(c)

clamping force holding test at the required relief value setting (where applicable).

AS 2359.1:2019

(see Figure 6.1) adjacent to the lifting point. The lifting point shall not show the structural capacity at

In addition, the nameplate shall show details of structural capacity at given position (lifting point) and state the load centre distance.

For the purpose of rating, the load centre distance or position of the jib attachment (which is supported by fork arms attached to the carriage), the measurement shall be taken from the vertical face of the fork arm (shank). For the purpose of rating, the load centre distance or position of the jib attachment (which is not the carriage.

Fork arm extensions (slipper forks) shall support 100 % of the load that is intended to be lifted. The Fork arm extensions shall be in accordance with AS 2359.15—2005 Clause 6.

AS 2359.1:2019

Section 12 Particular applications

For designation of alternative capacity, see Clause 2.4. For stability requirements, see Clause 3.2.5.

For designation of alternative capacity, see Clause 2.4 (in particular, Clause 2.4.2).

Trucks that are used to lift work platforms shall be in accordance with the following requirements: (a) The actual capacity at a 600 mm load centre of the trucks shall be equal to or greater than the following: (i)

For counterbalanced trucks, 1 800 kg or 5 times the combined mass of platform and platform rated load, whichever is the greater.

(ii) For reach trucks (retractable mast or fork arms shall be fully retracted) and straddle trucks, 1 000 kg or 3 times the combined mass of work platform and platform rated load, whichever is the greater.

Figure 12.2) that are supported by a truck and are used to elevate personnel shall be in accordance with the following requirements: (a) The platforms shall be designed for a rated load of 250 kg. (b) The platforms shall be designed so that they can be mounted on forks only in the correct position. Figure 12.2. (c)

The platforms shall have fork tunnels or clamps located within 150 mm min. and 250 mm max. of each side.

(d) The internal width of tunnels or clamps shall be not more than 50 mm greater than the fork arm width. (e) The internal height of tunnels or clamps shall be not more than 20 mm greater than the fork arm height. (f) Duplicate independent locks, shall be provided to secure the platform in the correct position in relation to the vertical portion of the forks and shall be clearly visible to personnel from within the platform. © Standards Australia Limited 2019 Bullivants | Page 316 of 692

AS 2359.1:2019

back to guard personnel from moving parts of the mast (see Figure 12.2). The parts of platforms shall conform with the following requirements: (i)

The outer dimension of the work platform shall be not larger than 1 200 mm × 1 200 mm. The work platform shall have an area of at least 0.6 m2 per person up to a maximum of two not exceed 15 mm in either width or length. The design loadings shall be in accordance with the relevant requirements of AS 1657.

attached to the truck.

inward-opening, and self-closing. (iii) The back shall be at least as wide as the work platform and at least 2 m high. The back shall with openings up to 9 mm2 shall be at least 100 mm from any moving portion of the mast. 2 shall be at least 150 mm from any moving portion of the mast. (h) An anchorage point for a safety harness shall meet the requirements of AS 5144.3. (i)

The use of the work platforms shall be limited to those situations where it is necessary to elevate personnel to perform special tasks of short duration and where it is not practicable to use a scaffold or equipment designed to elevate people, e.g. scissor lift. The platforms shall not be used for order picking, or for production or stores (administrative) types of activity such as stocktaking.

A durable, corrosion-resistant warning notice shall be permanently attached to the back of the platform (closest to the mast). It shall be in a position which is clearly visible to personnel within the platform, and display the information in Figure 12.1: Dimensions in millimetres

AS 2359.1:2019

Section 14 Marking

The marking requirements of AS 2359.6 and this Section shall apply.

Clause 10.5

Information to be marked on information plates shall be in accordance with AS 2359.6 and the following: (a) Trucks shall have an information plate(s), within direct view from the normal operating position for the actual capacity and any alternative capacities. Load charts (graphs) are not permitted to be (b) For trucks with a tilting mast, the actual capacity at maximum lift height mast vertical and mast tilted forward, and any alternative lift height with mast vertical and tilted forward and with load centred shall be shown. (c)

The requirements given in AS 2359.6—2013 Clause 6.3.1.1, Items (i) and (j) are not required except for towing tractors.

removal from the truck.

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AS 2359.6—2013

b) maintains a permanent record of the design, test(s) and implementation of the modification or alteration, c) approves and makes appropriate changes to the capacity plate(s), decals, tags and instruction handbook, and d) affixes a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered, together with the date of the modification or alteration and the name and address of the organization that accomplished those tasks.

6.3

Marking

6.3.1

Information plates

6.3.1.1

Trucks

Trucks shall be marked legibly and indelibly (e.g. weather-proofed, profiled letters) with at least the following details: a) name and address of the manufacturer or his authorized representative; b) designation of series or type and compliance with the requirements of this part of ISO 3691; c) serial number and year of manufacture; d) unladen mass of the truck in working order and without removable attachments, and without battery in the case of battery-powered trucks, but with fork arms or integral attachments, the actual mass being permitted to vary from the stated mass by up to 5 % or 1 000 kg, whichever is the lower of the two; e) actual capacity at maximum lift height with load centre distance; where a secondary lift is fitted to a truck, the capacity at maximum lift shall be determined with the secondary mast fully elevated; f)

actual capacities at other lift heights and load centre distances, if applicable;

g) actual capacity with each removable attachment fitted at the manufacturer's authorized lift height(s) and load centre(s), these actual capacities being easily readable by the operator in the normal operating position; h) on battery-powered trucks, the authorized maximum and minimum battery mass and the system voltage; i)

if fitted, the maximum supporting force on the towing point connection, in newtons;

if fitted, the drawbar pull on the towing point connection, in newtons;

k) the nominal power in kilowatts, e.g. marked on the engine or electric motor. Marking requirements are subject to regional requirements, additional to the requirements of this part of ISO 3691. See ISO/TS 3691-7:2011 and ISO/TS 3691-8. 6.3.1.2

Removable attachments

Removable attachments shall be marked legibly and indelibly (e.g. weather-proofed, profiled letters) with at least the following details: a) name and address of the attachment manufacturer or his authorized representative; b) model or type; c) serial number and year of manufacture;

www.standards.org.au

AS 2359.6—2013

d) mass of attachment, which may vary from the stated figure by up to lower of the two;

5 % or 200 kg, whichever is the

e) distance of the centre of gravity of the attachment from its mounting face on the truck; f)

rated capacity;

g) in the case of hydraulically or pneumatically operated attachments, the maximum operating pressure recommended by the attachment manufacturer; h) load centre, if applicable; i)

lost load centre distance;

the instruction The capacity of the truck and attachment combination shall be complied with .

6.3.1.3

Tractors

Tractors shall be marked legibly and indelibly (e.g. weather-proofed, profiled letters) with at least the following details: a) name and address of the manufacturer or the authorized representative; b) designation of series or type; c) unladen mass of the tractor in working order without battery for battery-powered tractors; the mass may vary from the figure shown by up to 5 % or 1 000 kg, whichever is the lower; d) serial number and year of manufacture; e) on battery-powered tractors, the authorized minimum and maximum battery mass and the system of voltage; f)

the nominal power in kilowatts, e.g. marked on the engine or electric motor;

g) the maximum supporting force on the tow-hook, in newtons; h) the drawbar pull, in newtons, and the period of time during which this pull can be exerted. 6.3.1.4

Marking of controls

Controls shall be legibly and indelibly marked (e.g. weather-proofed, profiled letters) with graphic symbols indicating the function(s), except where these are obvious, e.g. accelerator pedal. Each symbol shall be affixed on, or in close proximity to, the control to which it applies. Control symbols shall comply with ISO 3287, for existing symbols. 6.3.2

Information plate for trucks operating in special conditions

If a truck is designed to operate in special conditions (see 4.1.1. and 4.8.2), the manufacturer shall provide, where appropriate, and in addition to the information provided in the instruction handbook, an information plate on the truck identifying those special conditions of use, including capacity if different from the capacity during normal operation (see 4.1.2). 6.3.3 6.3.3.1

Other information Marking for slinging of trucks

Locations for slinging shall be clearly indicated on the truck or shall be declared in the instruction handbook (see 6.2).

www.standards.org.au

AS 2550.1—2011

Australian Standard® Cranes, hoists and winches—Safe use Part 1: General requirements

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AS 2550.1—2011

SEC TION

INS P E C TIO N O F R O PES , AND LIFT ING GEAR

HOOKS

8.1 ROPES 8.1.1 Replacement of ropes The examination and discard criteria for wire ropes and their replacement shall be in conformance with the crane manufacturer’s guidelines or, where not available, AS 2759 and AS 1418.1. For multiple rope hoists, the ropes shall be matching ropes of the same construction and tensile strength. 8.1.2 Rope reeving Where it is possible to vary the number of falls of the hoist rope or parts of rope in the luffing system, these shall be in accordance with instructions written in accordance with this Standard for boom and jib lengths and loads to be lifted.

Accessed by Wesfarmers Industrial and Safety Ltd on 16 Mar 2018 (Document currency not guaranteed when printed)

NOTES: 1

If a load moment system is fitted, the system generally operates accurately only when its setting corresponds to the length of boom or jib fitted and the type of rope reeving adopted.

Where a crane is fitted with a load-sensing device, the device may require adjustment after a change of reeving before the crane is placed in service.

8.1.3 Rope guards or keepers Where rope guards or keepers are fitted to sheaves, hook blocks or drums, they shall remain in their correct positions and shall be removed only for the purposes of maintenance, inspection or adjustment. NOTE: This is of particular importance if, under certain circumstances, the rope system develops a slack rope condition. Failure to observe this could allow a rope to run off a sheave or drum and become trapped or damaged.

8.1.4 Guide rollers and guide sheaves Where guide rollers or guide sheaves are fitted, they shall be checked frequently to ensure that they are free to rotate. Where boom or jib protective strips are fitted, they shall be frequently checked for security and serviceability. NOTE: A seized roller or sheave may cause serious damage to a rope, leading to its premature failure.

8.1.5 Rope drums and sheaves Rope drums and sheaves shall be examined for wear, at regular intervals. Sheaves shall revolve true and freely on their supporting shafts and particular attention shall be given to lubrication. 8.1.6 Rope terminal fittings Wire rope terminations shall be carried out in accordance with manufacturer’s specifications. In the absence of manufacturer specifications, terminal fittings as specified in AS 2759 shall be used to attach a rope to a drum, anchorage, hook block or structure of the crane. Improvised fittings shall not be used. Attention shall be given to the assembly of wedge and socket fittings, and such fittings shall be provided with a rope tail clip as specified in AS 2076.

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AS 2550.1—2011 8.1.7 Rope lengths Ropes of the correct length shall be fitted. Before hoisting operations commence following installation of a new rope or a change of configuration, the rope drums shall be checked in the extreme spooling conditions to ensure that the rope lengths are correct. The settings of the limit devices shall be checked. NOTE: With variable boom or jib lengths it may be necessary to fit a specific length of rope for a particular boom or jib length and rope reeving combination. Too short a rope may result in the rope completely paying out with the entire load being taken by the anchorage. Too long a rope may exceed the drum spooling capacity and result in the rope riding over the flanges and becoming trapped in the machinery causing severe damage and possibly premature rope failure.

8.1.8 Rope stretch Rope stretch may create problems with the setting of hoisting limiting devices and the overfilling of the drum. Frequent inspections, particularly during the early life of the installed rope, shall be carried out to determine whether the limiting devices require adjustment or the rope needs to be cut back to the appropriate length. 8.1.9 Examination of ropes

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A visual examination shall be performed during the pre-operational inspection for kinking, birdcaging, damage and correct reeving. A thorough examination shall be carried out by a competent person during the routine inspection phase. The acceptance and discard criteria shall be in accordance with AS 2759. NOTE: Rope wear is affected by climatic and environmental conditions, e.g., saline, corrosive or abrasive atmosphere.

Particular attention should be paid to those sections of rope close to rigid terminal fittings. NOTE: Ropes that are composed or more than one layer of strands, such as non-rotating ropes, may deteriorate internally at the interface between the layers.

If multi-layer drums are used, the examinations hall include not only that part of the rope that is in constant use, but also that part of the rope that remains spooled and inoperative on the drum for long periods. Boom and fly-jib suspension ropes are often placed at positions remote from the basic crane structure. Such ropes shall be carefully examined, particularly those sections lying round sheaves. 8.2 HOOKS AND HOOK BLOCKS The hook or hook block shall be capable of handling the nominated load. The hook shall not be loaded beyond its working load limit. To prevent displacement of the sling or load, the hook should be provided with a safety catch or other effective device to minimize the risk of the sling or load becoming detached. The hook shall not be overcrowded. NOTE: Where multiple slings are used, they should be attached to a bow-shackle, which is then placed on the hook. This prevents the danger of the hook being strained owing to the spread of the slings and also the danger of a sling fouling the safety catch or slipping over the point of the hook.

All end links, rings or shackles shall ride freely on the hook. NOTE: When the crane is working with a single fall of rope and the load is set down, thus relieving the tension in the hoist rope, the hook can spin. Personnel should always exercise care when approaching the hook to disconnect the sling.

Bullivants | Page 325 of 692

AS 2550.1—2011 8.3 LIFTING GEAR 8.3.1 Identification and marking Each lifting attachment shall be clearly and permanently marked in accordance with AS 4991. 8.3.2 Inspection All lifting attachments shall be inspected immediately prior to use. Regular inspection, consistent with the design and usage of the attachments, shall be carried out by a competent person, and the extent of each inspection shall be consistent with the design and usage of the attachment.

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NOTE: See Clause 7.41 for more information.

Bullivants | Page 326 of 692

AS/NZS 2693:2007

Australian/New Zealand Standard™ Vehicle jacks

Originated as AS 2693—1987. Previous edition AS/NZS 2693:2003. Fourth edition 2007.

COPYRIGHT © Standards Australia/Standards New Zealand All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher. Jointly published by Standards Australia, GPO Box 476, Sydney, NSW 2001 and Standards New Zealand, Private Bag 2439, Wellington 6020 ISBN 0 7337 8009 1 Bullivants | Page 327 of 692

AS/NZS 2693:2007

CONTENTS

1 2

Page SCOPE .............................................................................................................................. 4 APPLICATION ............................................................................................... 4

REFERENCED DOCUMENTS...................................................................... 4

DEFINITIONS ............................................................................................ 4

DESIGN AND CONSTRUCTION ................................................................. 6

PERFORMANCE ............................................................................................ 9

MARKING .................................................................................................... 10

INSTRUCTIONS ...................................................................................... 12

APPENDICES A SUMMARY OF REQUIREMENTS FOR VEHICLE JACKS ..................... 14 B HEAD CAP ENGAGEMENT AND STABILITY TESTS. .......................... 15 C DURABILITY, OPERATING FORCE AND OVERTRAVEL TESTS ...... 17 D STOP TEST DURING THE LOWERING OF THE JACK .......................... 21 E LOSS OF HEIGHT TEST ............................................................................. 22 F OVERLOAD TEST ....................................................................................... 23

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AS/NZS 2693:2007

6.4 Lowering When the jack is tested in accordance with Appendix D, the operator shall be able to stop the head cap at any point during the descent within a distance equal to 5 percent of the full range of travel of the head cap, without hazard to the operator or damage to the jack. 6.5 Loss of height with time When determined in accordance with Appendix E, the loss of height of the head cap of the jack, other than that which occurs with the initial deflection, shall not exceed 5 mm at the conclusion of 30 min. 6.6 Overload protection If a jack is fitted with a means of protection against raising the head cap under a load in excess of its nominated capacity, such protection shall operate at the nominated capacity +15, −0 percent. 6.7 Overload capacity

When tested in accordance with Appendix F, a jack shall comply with the following requirements: (a)

The jack shall not collapse.

(b)

The load supported by the jack shall not suffer a loss of height greater than 5 percent of the initial height of the load.

(c)

The jack shall be capable of lifting its nominated capacity load through one lifting cycle using an operating force not exceeding that specified in Clause 6.3.

6.8 Minimum capacity

6.8.1 General purpose jacks A general purpose jack shall have a nominated capacity of not less than 750 kg. 6.8.2 Specific vehicle jacks A specific vehicle jack shall have a minimum capacity which is not less than the maximum load applied to the jack when lifting any wheel clear of the ground on any of the models or model designations of vehicles with the vehicle at its maximum load mass.

6.8.3 High lift jacks A high lift jack shall have a nominated minimum load which is necessary to allow the jack to be lowered step by step without dropping the vehicle.

6.8.4 Caravan/trailer jacks A caravan/trailer jack shall have a nominated capacity which is not less than the maximum load applied to the jack when lifting any wheel clear of the ground on a caravan/trailer loaded to its aggregate trailer mass. 7 MARKING 7.1 Jack marking NOTES: 1

A label with a surface which can absorb grease is unsuitable.

Plastics labels complying with AS 2581 may be suitable.

7.1.1 Jacks other than specific vehicle jacks 7.1.1.1 General requirements Jacks other than specific vehicle jacks shall be permanently and legibly marked with the following information.

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AS/NZS 2693:2007

(a)

The name and address in Australia or New Zealand of the manufacturer, importer or other suppliers of the jack.

(b)

The nominated capacity in kilograms stated as 'Working Load Limit ..... kg'.

(c)

Clear and adequate instructions regarding the operation of the jack.

(d)

The manufacturing batch identification.

7.1.1.2 For high lift jacks In addition to the general requirements of Clause 7.1.1.1, high lift jacks shall be permanently and legibly marked with a warning notice, or words to the same effect, in letters not less than 5 mm, as follows: WARNING: NOT FOR VEHICLE MAINTENANCE OR WHEEL REMOVAL. DO NOT GET UNDER A RAISED VEHICLE.

and THIS JACK MUST HAVE A MINIMUM LOAD OF X KG (manufacturers to nominate a load) ON IT TO LOWER STEP-BY-STEP, OTHERWISE THE LIFTING MECHANISM WILL SLIDE DOWN TO THE BASE PLATE DROPPING THE VEHICLE.

7.1.1.3 For other than high lift jacks In addition to the general requirements of Clause 7.1.1.1, jacks other than high lift jacks shall be permanently and legibly marked with a warning notice, or words to the same effect, in letters not less than 5 mm, stating: WARNING: DO NOT GET UNDER A VEHICLE THAT IS SUPPORTED BY A JACK.

7.1.1.4 For hydraulic jacks In addition to the general requirements of Clause 7.1.1.1, hydraulic jacks shall be permanently and legibly marked with a statement specifying the correct hydraulic fluid for use with the jack and a requirement that it be kept at the recommended level.

7.1.1.5 For caravan/trailer jacks In addition to the general requirements of Clause 7.1.1.1, caravan/trailer jacks shall be permanently and legibly marked as follows: (a)

With a warning notice, or words to the same effect, in letters not less than 5 mm stating: WARNING: USE ONLY WITH CORRECT ENGAGEMENT FITTING.

(b)

With the name of the manufacturer of the specified engagement fitting.

7.1.2 Specific vehicle jacks Specific vehicle jacks shall be permanently and legibly marked with the following information: (a)

The name or trademark of the vehicle manufacturer.

(b)

The model or model designations of vehicles with which the jack is intended to be used.

(c)

Clear and adequate instructions regarding the operation of the jack. NOTE: The instructions may be provided in pictogram form.

(d)

Advice to consult the vehicles owners manual for further instructions. NOTE: This advice may be provided in pictogram form.

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AS/NZS 2693:2007

(e)

For hydraulic jacks, a statement specifying the correct hydraulic fluid for use with the jack and a requirement that it be kept at the recommended level.

(f)

Warning advice against getting under a vehicle that is supported by a jack. NOTE: This warning advice may be provided in pictogram form.

7.2 Packaging marking For general purpose jacks, high lift jacks and caravan/trailer jacks, the following information shall be clearly marked on the packaging of the jack or if there is no packaging, on a leaflet attached to the jack: (a)

The ‘height lowered’, being the minimum height of the head cap, in millimetres.

(b)

The ‘height raised’, being the maximum height of the head cap, in millimetres.

(c)

The nominated capacity in kilograms stated as ‘Working Load Limit . . . kg’.

8 INSTRUCTIONS 8.1 General If assembly is required, adequate assembly instructions together with a parts list and an exploded diagram of the jack shall be clearly marked on the packaging or within the package or if there is no packaging then on a leaflet attached to the jack. In addition to the assembly information and the instructions marked upon the jack in accordance with Clause 7.1.1.1(c) maintenance and self-usage instructions shall be supplied with the jack in accordance with Clauses 8.2 and 8.3. 8.2 Maintenance instructions Any necessary procedures for maintenance, including lubrication requirements and details for servicing the hydraulic system, if any, shall be supplied with the jack. 8.3 Safe usage instructions The following information shall be supplied with the jack: (a)

(b)

(c)

For general and specific purpose jacks: (i)

That the jack should be used on level firm ground wherever possible.

(ii)

That it is recommended that the wheels of the vehicle be chocked, and that no person should remain in a vehicle that is being jacked.

(iii)

That no person should place any portion of their body under a vehicle that is supported by a jack.

(iv)

For specific vehicle jacks that are supplied as replacements for jacks supplied with a new vehicle, the information shall be supplied with the jack.

For high lift jacks: (i)

That no person should place any portion of their body under a vehicle that is supported by a jack.

(ii)

The following warning, or words to the same effect, for high lift jacks only: ‘This jack must have a minimum load of X kg (manufacturers to nominate a load) on it to lower step-by-step, otherwise the lifting mechanism will slide down to the base plate dropping the vehicle'.

For caravan/trailer jacks: (i)

That the jack should be used on level firm ground wherever possible.

(ii)

That it is recommended that the wheels of the caravan/trailer be chocked, and that no person should remain in a caravan/trailer that is being jacked.

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AS/NZS 2693:2007

(iii)

That no person should place any portion of their body under a caravan/trailer that is supported by a jack.

(iv)

The caravan/trailer should be attached to the towing vehicle.

NOTES: 1

For a specific vehicle jack or caravan/trailer jack that is supplied with a new vehicle, this information may be included in the vehicle owner’s manual or it may be marked on the vehicle.

If all of the information specified in Clause 8 is permanently and legibly marked on the jack, a separate set of instructions need not be supplied.

Manufacturers making a statement of compliance with this Australian/New Zealand Standard on a product, packaging, or promotional material related to that product are advised to ensure that such compliance is capable of being verified.

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AS 2740—2001

AS 2740

Australian Standard™ Wedge-type sockets

Bullivants | Page 333 of 692

AS 2740—2001 7.2 Information The following information shall be marked: (a)

Manufacturer’s identification.

(b)

Nominal size.

(c)

Identification marking to correlate to the batch number

NOTE: Manufacturers making a statement of compliance with this Australian Standard on a product, packaging, or promotional material related to that product are advised to ensure that such compliance is capable of being verified

8 TESTING OF MECHANICAL PROPERTIES Compliance of each design with the requirements of Clause 6 shall be demonstrated. The test of each design is known as the type test, which determines the adequacy of the design for achieving the required performance. Each change in manufacturing process, grade of material, design and size necessitates separate type testing, to demonstrate compliance with the requirements of Clause 6. Where a sample is subjected to the relevant destructive test force listed in Table 2, failure of any component other than the wire rope should result in rejection of the design or batch. NOTE: Means of demonstrating compliance with this Standard are given in Appendix F.

9 MANUFACTURING PROOF TESTING AND QUALITY CONTROL 9.1 Proof loading If required by the customer or user, each wedge-type socket shall be subjected to a force that is not less than the relevant proof test force listed in Table 2, applied under the conditions specified in Appendix E. 9.2 Requirements The wedge-type socket shall— (a)

withstand the application of the proof force, without sustaining damage that may detrimentally affect its operation, intended function or safety, without the rope slipping; and

(b)

after proof loading, be free from any deleterious permanent set or defects that can be detected by visual inspection.

A competent person (see Clause 3.2) shall be satisfied that these requirements have been met. 9.3 Mechanical properties Compliance of mechanical properties shall be demonstrated by meeting the requirements of Clause 6. 9.4 Test certificate Any proof testing shall be recorded on a test certificate, which shall bear the following information: (a)

Description.

(b)

Nominal size.

(c)

Surface finish, if other than painted.

Bullivants | Page 334 of 692

AS 2740—2001 TABLE 2 TEST FORCES

Nominal size (see Clause 3.4) mm

Minimum breaking force of test rope, B (see Note 1) kN

8 9 10

Test force, kN (see Note 2) Destructive tests, minimum (see Note 3)

Proof test (see Note 4)

40.2 51.1 63.1

32.2 40.9 50.5

16.1 20.5 25.3

11 12 13

76.3 90.8 107

61.1 72.7 85.6

30.6 36.4 42.8

14 16 18

124 161 204

99.2 129 164

49.6 64.4 81.6

20 22 24

252 305 363

202 244 291

101 122 146

26 28 32

426 494 646

341 396 517

171 198 259

36 40 44

817 1010 1220

654 808 976

327 404 488

48 52 56

1450 1710 1980

1160 1370 1590

580 684 792

2270

1820

908

NOTES: 1

These values are based on the test rope required by Appendix E for 6 × 19 and 6 × 36 IWRC construction groups 1770 Grade, as specified in AS 3569.

Where tensile grades or different constructions with large capacities are used, the socket shall be type tested with the particular rope. A destructive test force of 0.8 times the breaking force of that rope and a proof force of 0.4 times the breaking force of that rope shall apply.

Minimum destructive test force = 0.8B, rounded up to three significant figures.

Production proof test force = 0.4B, rounded up to three significant figures.

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AS 2741—2002

(Incorporating Amendment Nos 1 and 2) Reconfirmed 2014

Australian Standard® Shackles

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AS 2741—2002

7 MARKING 7.1 General Shackle bodies shall be permanently and legibly marked with the information required by Clause 7.2, the marking being either raised or indented. Where the marking is indented, the marks shall not have sharp edges nor reduce the strength of the shackle. The marking should be located in accordance with Figure 1. 7.2 Information The following information shall be marked: (a)

Manufacturer’s identification.

(b)

Quality Grade, as M or 4, or S or 6.

(c)

WLL.

(d)

Identification marking to correlate the shackle to the test certificate.

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Identification mark and symbol

Identification mark and symbol Gauge length G1

Gauge length G1

Gauge length G2

(a) Dee shackles

(b) Bow shackles

FIGURE 1 TYPICAL POSITIONS FOR MARKING SHACKLES

8 TESTING OF MECHANICAL PROPERTIES Compliance of each design and each batch with the requirements of Clause 6 shall be demonstrated. The test of each design is known as the type test, which determines the adequacy of the design for achieving the required performance. Each change in manufacturing process (including heat treatment), grade of material, design and size shall necessitate separate type testing, to demonstrate compliance with the requirements of Clause 6. NOTE: Means for demonstrating compliance with this Standard are given in Appendix G.

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AS 2741—2002

9 QUALITY CONTROL DURING MANUFACTURING 9.1 General During manufacturing, the quality of shackles shall be controlled by either— (a)

proof testing every shackle in accordance with Clause 9.2; or

(b)

a quality control system complying with Clause 9.3.

NOTES: 1

Proof testing of every shackle may be required by the purchaser, the regulatory authority or the user.

Figure 2 (which is located after Clause 9.4) illustrates the options given in Clause 9.

9.2 Proof testing

9.2.1

Application

Clause 9.2 applies where option (a) in Clause 9.1 is chosen and where otherwise required.

9.2.2

Method

Each shackle is subjected to a proof force (see Appendix D), applied under the conditions specified in Appendix F, of—

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(a) (b)

for shackles with a WLL of not more than 55 t, [(WLL in tonnes) × 2 × 9.81] kN; and

for shackles with a WLL of more than 55 t, [(WLL in tonnes + 50) 9.81] kN.

9.2.3 Requirements The shackle shall— (a)

withstand the application of the proof force, without sustaining damage that may affect its operation, intended function or safety; and

(b)

after proof loading— (i)

be free from any deleterious permanent set or defects that can be detected by visual inspection; and

(ii)

for gauge lengths G1 and G2, as defined in Figure 1, of— (A)

more than 25 mm, not be deformed by more than 2% of the initial dimension; and

(B)

not more than 25 mm, not be deformed by more than 0.5 mm.

Any shackles that fail this test shall be rejected. A2

A competent person (see Clause 3.1) shall ensure that these requirements have been met. 9.3 Using a quality control system

9.3.1

Application

Clause 9.3 applies where option (b) in Clause 9.1 is used. Clause 9.3.2 applies to shackles with a WLL of not more than 25 t. Clause 9.3.3 applies to shackles with a WLL of more than 25 t.

9.3.2

WLL of not more than 25 t

For shackles with a WLL of not more than 25 t, if a quality control system is used, the quality control system shall be undertaken by a testing laboratory that is accredited to AS ISO/IEC 17025, and the following apply:

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AS 2741—2002

APPENDIX D

DETAILS OF SHACKLE BODIES

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(Normative)

www.standards.org.au Bullivants | Page 339 of 692

AS 2741—2002

d Body R1 d

L Pin

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Shown with a Figure E1 type pin. Typical types of pin are shown in Figures E1 to E6 of Appendix E. 1

Nominal size

Dimension, mm (Tolerance +8%, -5%)

7 WLL t

Test force, kN Destructive test

Proof test

0.25 0.50 0.75

14.8 29.5 44.2

5.0 9.9 14.8

38 44 51

1.5 2.0 3.0

88.3 118 177

29.5 39.3 58.9

95 105 114

57 63 70

3.8 5.0 6.0

224 295 354

74.6 98.1 118

67 70 76

127 137 146

76 89 95

7.0 9.5 11

413 560 648

138 187 216

51 54 57

83 92 98

156 178 187

102 108 114

13 14 16

766 825 942

256 275 314

54 57 63

60 63 73

105 108 121

197 210 235

121 127 146

18 20 25

1060 1180 1480

354 393 491

70 76 79

79 86 89

133 146 149

260 279 292

159 171 178

30 35 40

1770 2070 2360

589 687 785

89 102 114

102 114 127

171 191 219

330 375 419

203 229 254

50 65 80

2950 3830 4710

981 1130 1280

6 10 13

10 13 16

13 19 28

25 38 54

19 25 32

16 19 22

19 22 25

32 38 44

63 73 83

25 29 32

29 32 35

51 54 60

35 38 41

38 44 48

44 48 51

54 57 63

FIGURE D1 QUALITY GRADE M OR 4 DEE SHACKLES

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AS 2741—2002

d Body R1 d

L Pin

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Shown with a Figure E7 type pin. Typical types of pin are shown in the following figures of Appendix E: (a) shackle sizes of less than 12 mm, Figure E7. (b) shackle sizes of not less than 12 mm, Figures E7 and E8. 1

Nominal size

Dimension, mm (Tolerance +8%, -5%)

7 WLL t

Test force, kN Pin type Destructive test

Proof test

29.5 44.2 58.9 88.3

9.9 14.8 19.7 29.5

6 8 10 11

8 10 11 13

12 13 17 18

22 26 32 37

17 21 25 27

0.5 0.75 1.0 1.5

13 16 19

16 22 22

21 27 32

41 51 60

33 40 48

2.0 3.2 4.7

118 189 277

22 25 29

25 29 32

37 43 46

71 81 90

54 60 67

6.5 8.5 9.5

383 501 560

128 167 187

32 35 38

35 38 41

52 57 60

100 113 124

76 84 92

11 13.5 17

707 795 1010

236 265 334

44 51 57

51 57 63

73 83 95

146 171 181

110 127 143

25 35 42.5

1480 2070 2510

491 687 834

63 76 89

70 83 95

105 127 146

203 229+ 267

153 165 203

55 85 120

3240 5010 7070

1080 1330 1670

102

108

165

318

229

150

8830

1970

Figure E7

39.3 62.8 92.3

Figures E7 and E8

FIGURE D2 QUALITY GRADE S OR 6 DEE SHACKLES

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AS 2741—2002

d Body R1 d R2

B 2

L R2 Pin

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Shown with a Figure E7 type pin. Typical types of pin are shown in the following figures of Appendix E: (a) For shackle sizes of less than 12 mm, Figure E7. (b) For shackle sizes of not less than 12 mm, Figures E7 and E8. 1

Nominal size

Dimension, mm (Tolerance +8%, -5%)

8 WLL t

Test force, kN Pin type Destructive test

Proof test

0.33 0.50 0.75 1.0 1.5

19.5 29.5 44.2 58.9 88.3

6.5 9.9 14.8 19.7 29.5

33 40 48

2.0 3.2 4.7

118 189 277

39.3 62.8 92.3

84 95 108

54 60 67

6.5 8.5 9.5

383 501 560

128 167 187

83 92 98

119 133 146

76 84 92

12 13.5 17

707 795 1010

236 265 334

73 83 95

127 146 160

178 197 222

110 127 143

25 35 42.5

1480 2070 2510

491 687 834

70 83 95

105 127 146

184 200 241

267 330 381

152 165 203

55 85 120

3240 5010 7070

1080 1330 1670

108

165

279

432

229

150

8830

1970

5 6 8 10 11

6 8 10 11 13

10 12 13 17 18

15 20 21 26 29

22 29 31 37 43

14 17 21 25 27

13 16 19

16 19 22

21 27 32

33 43 51

48 61 72

22 25 29

25 29 32

37 43 46

58 68 74

32 35 38

35 38 41

52 57 60

44 51 57

51 57 63

63 76 89

102

Figure E7

Figures E7 and E8

FIGURE D3 QUALITY GRADE S OR 6 BOW SHACKLES

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AS 2741—2002

APPENDIX E

DETAILS OF TYPICAL SHACKLE PINS (Informative) w 2d

0.25D

0.75D

d D

1.50D

1.20D

0.50D 0.60D

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89 mm

FIGURE E1 SCREWED AND COLLARED PIN WITH EYE IN RECTANGULAR HEAD FOR QUALITY GRADE M OR 4 SHACKLES

0.65D

w 2d

0.73D

w d D 1.25D

1.20D

0.50D D

89 mm

FIGURE E2 SCREWED AND COLLARED PIN WITH EYE IN ROUNDED HEAD FOR QUALITY GRADE M OR 4 SHACKLES

0.15D

w 2d

0.15D wd D

0.15D 1.30D

90°

0.20D D

63 mm

FIGURE E3 SCREWED PIN WITH SLOTTED COUNTERSUNK HEAD FOR QUALITY GRADE M OR 4 SHACKLES

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AS 2741—2002 w 2d

0.25D 0.25D 0.07D Hole

(0.50D 1 mm)

wd D

0.80D

1.50D

90°

0.10D 0.60D D

63 mm

FIGURE E4 SCREWED PIN WITH SOCKETED COUNTERSUNK HEAD FOR QUALITY GRADE M OR 4 SHACKLES 1.50D

w 2d 0.90D

0.60D

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w 2d D

0.90D 0.20D

90 mm

FIGURE E5 BOLT, NUT AND SPLIT PIN FOR QUALITY GRADE M OR 4 SHACKLES

0.25D

w 2d 0.80D w 2d

0.55D D

1.50D 0.28D

0.30D

1.50D

0.25 D

0.50D 0.65D

FIGURE E6 COLLARED PIN AND FORELOCK FOR QUALITY GRADE M OR 4 SHACKLES

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AS 2741—2002

1.50D

0.25D

1.25D

w 2d

0.50D 0.70D wd D 1.25D

0.50D

FIGURE E7 SCREWED AND COLLARED PIN WITH EYE FOR QUALITY GRADE S OR 6 SHACKLES

0.60D

0.90D

0.35D

0.60D

w 2d

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0.20D

FIGURE E8 BOLT, NUT AND SPLIT PIN FOR QUALITY GRADE S OR 6 SHACKLES

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AS 2741—2002

APPENDIX F

CONDITIONS FOR APPLICATION OF TEST FORCES (Normative) The following conditions apply to the application of test forces to shackles: The testing machine shall be calibrated in accordance with AS 2193 and shall be capable of Grade A results when testing mechanical properties (see Clause 6) and Grade C results when proof testing (see Clause 9.2).

(b)

Manufacturing processes, other than proof loading and any application of temporary protective coatings for storage purposes, shall be completed.

(c)

The interface of the testing tooling shall be not more than two-thirds of the inside width B or W of a bow shackle or W of a dee shackle.

(d)

The test force shall be applied to the shackle in tension along the centre-line that lies on the central plane of the body and the pin, is normal to the central axis of the pin and passes through the centre of the opening between the ends of the body.

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(a)

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AS 2759—2004

Australian Standard™ Steel wire rope—Use, operation and maintenance

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AS 2759—2004

SEC TION 6

P OUR ED

S OC KETS

6.1 GENERAL Poured sockets attached by means of resin or metal are an efficient means of providing terminal attachments for wire ropes. The nomenclature of parts of sockets is illustrated in Figure 6.1.

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The load is transferred between the rope and the socket forging or casting by means of adhesion between the rope wires and the metal or resin used in the socket bowl and subsequent wedging action provided by the conical socket bowl. The efficiency of socketing depends on the effectiveness of the bond between the rope’s wires and the metal or resin in the socket. Care should be taken to follow the correct procedure. Properly applied poured socket attachments will withstand the actual breaking force of the wire rope.

FIGURE 6.1 NOMENCLATURE OF PARTS OF SOCKETS

6.2 QUALIFYING AND QUALITY CONTROL 6.2.1 Personnel Personnel carrying out qualifying or quality control shall have had adequate training in socketing and samples of their work shall be tested. 6.2.2 Poured socket systems Poured socket systems shall have passed qualifying tests. 6.2.3 Type testing Appropriate tests of poured socket systems for qualifying or quality control include the following: (a)

Destructive type testing of the terminations, by meeting the efficiency specified in Table 5.2.

(b)

Routine sample type testing (which is recommended).

(c)

The size, range and construction of wire rope and strand to be taken into consideration.

(d)

A risk assessment for some applications (wherever appropriate).

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AS 2759—2004

6.2.4 Proof testing Wire rope assemblies manufactured with poured sockets shall be proof-loaded in accordance with AS 1666.1. Where possible, any other socket terminations shall be proof- loaded to 40% of the minimum breaking force of the wire rope. 6.3 SPECIFICATIONS FOR SOCKETS 6.3.1 General purpose sockets Open- and closed-type forged-steel sockets for 1770 grade wire ropes have been standardized for general engineering purposes by overseas Standards organizations. Sockets should comply with one of the following relevant Standards, or another recognized Standard: ISO 3189-1, ISO 3189-2, ISO 3189-3, BS 463.1, BS 463.2, Federal Specification RRS-550D. BS 463 specifies sockets with proof loads based on approximately two-fifths of the minimum breaking load of ropes in the 6 × 19 group of Grade 1770 MPa. The working load for these sockets should not exceed one-half of the specified proof load. Pins of sockets complying with BS 463 have been designed on the assumption that the load is distributed over their length.

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6.3.2 Sockets for strand and higher capacity wire rope Sockets for strand and higher capacity wire rope are used in applications such as strand guys and pendants on crane booms in construction and on excavating equipment. These sockets are generally designed with increased dimensions (e.g., increased bowl lengths) to provide a greater area for bonding of the resin or metal. Socket manufacturers recommendations shall be considered. 6.3.3 Reuse of sockets

Refer to Bullivants Policy next page

Where sockets are to be reused, it is necessary to prepare them by melting, pressing or burning out remaining socketing material; however, care shall be taken that the temperature used does not exceed 450°C. Normalizing or stress relieving should be considered. Sockets should be identified by size and suitability for their intended application. Visual inspections shall be carried out for defects, wear, damage and dimensional change. Magnetic particle inspections are commonly used to aid this process, particularly for larger sized sockets in highly loaded applications. 6.3.4 Inspection of sockets prior to socketing Ensure that the socket selected is fit for its purpose. Sockets should be clean and free from defects. Ensure all dirt, grease and scale has been removed from the inside of the socket bowl. 6.4 SOCKETING MATERIAL 6.4.1 Resin socketing For resin socketing of wire rope or strand, only specific resins for socketing purposes shall be used and resin manufacturer’s instructions shall be followed. 6.4.2 Metal socketing For metal socketing, metal complying with DIN 3092-1 or white metal complying with BS 643 should be used. When metal socketing strand, zinc of 99.99% purity should be used. 6.4.3 Lift applications Special requirements for socketing material in lift installations are given in AS 1735.2.

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AS 2759—2004

SEC TION

1 3

R OP E

INS PEC TION

13.1 REGULAR INSPECTION The handling of loads by ropes requires adequately designed and maintained equipment. The design of lifting appliances does not normally allow for an indefinite rope life. A rope should be regarded as a wearing component. There is danger in the belief that a rope does not need maintenance or that it will last forever. Thus, service life is also dependent upon regular inspections of the rope’s condition. A deteriorating rope should be removed from service while still in a serviceable condition, i.e., before its strength decreases to a level where failure may occur. The rope shall be discarded immediately an inspection shows its strength to have diminished to an unacceptable level (refer to Section 14). Inspections of wire ropes should be made by competent persons involved in the maintenance and inspection of lifting appliances.

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The inspection should include the following measures: (a)

Record the rope condition so that the progressive deterioration of the rope can be monitored (see Clause 13.5). The different types of rope deterioration are considered in Section 14.

(b)

Determine whether the rope is suitable for continued use.

(c)

Particular attention should be paid to the rope at points of attachment to the appliance.

(d)

Periodically check drums and sheaves, to ensure that all these components are free to rotate. Stiff or jammed sheaves or rollers wear heavily and unevenly, causing severe abrasion of the rope. Ineffective equalizing sheaves can give rise to unequal loading in the rope reeving. With small rope movement, the equalizing sheave pins tend to wear out, restricting the movement of the sheave and causing the rope to skid under pressure.

(e)

Investigate whether any defect in the appliance is assisting the deterioration. Any defect should be eliminated before a new rope is fitted.

(f)

Check whether an improvement in the working conditions or increase of maintenance could reduce the rope deterioration.

(g)

Investigate whether any kind of modification is necessary to reduce the rate at which the rope is deteriorating.

NOTE: Much experience can be gained by opening up and completely inspecting discarded ropes, logging findings and causes found for deterioration, and displaying on boards samples cut from discarded ropes. Confidence in inspection can be built up by the submission of samples of discarded ropes of importance to a test house for testing to destruction.

13.2 SPECIAL INSPECTION Whenever any of the following conditions apply, the ropes should be given a particularly critical inspection before they are further used: (a)

An accident has occurred which may have caused damage to the rope or to its termination.

(b)

A new deteriorating condition is recognized.

(c)

A rope has been brought back into operation after dismantling followed by reassembly.

(d)

A lifting appliance is reused after having been out of operation for a period.

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AS 2759—2004

13.3 FREQUENCY It is necessary to regularly inspect ropes, and any equipment on which ropes are used. The frequency of inspection will be influenced by the nature of the equipment and its working conditions, and should be more frequent with advancing age. Depending upon the working conditions, wire rope may need to be visually inspected each working day with the objective of detecting general deterioration and deformation. In order to determine the frequency of inspection, consideration should be given to the following: (a)

Environmental conditions.

(b)

Severity of the operating conditions.

(c)

Type of appliance.

(d)

Mechanism classification as specified by AS 1418.1.

(e)

Results of previous inspections.

(f)

The length of time the rope has been in service.

(g)

The number of operating cycles the rope has been in service.

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13.4 MEASURING DIAMETER The diameter of a wire rope should be measured with a suitable device such as rope callipers (see Figure 13.4) and based on at least two readings at least 1.0 m apart along the length of the rope. The measured diameter is the average of these readings. The measuring jaws should be of sufficient length to lap at least two strands on opposite sides of the rope.

FIGURE 13.4 MEASUREMENT OF DIAMETER OF WIRE ROPES

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AS 2759—2004

13.5 INSPECTION LOG Users should provide a log for the recording of information from each inspection of the rope. Regular recording of the condition of the rope should be made together with the service results obtained (i.e., in terms of work done and performance). Figure 13.5 shows a typical log. Accurate recording of information by the examiner may be used to predict the performance of a particular type of rope on a lifting appliance. Such information is useful in regulating maintenance procedures and stock control of replacement rope. Any forecasting should not have the effect of relaxing inspections or prolonging the operating periods beyond that indicated by the criteria discussed in Clauses 13.1 to 13.3. 13.6 POSITIONS

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Although wire ropes should be inspected throughout their length, particular care should be taken at the following positions (see also Figure 13.6): (a)

The terminations at the end of both moving and stationary ropes.

(b)

Any part of a rope that passes through a block or over a sheave.

(c)

Appliances performing a repetitive operation.

(d)

Any part of a rope that lies over sheaves while the appliance is in a loaded condition.

(e)

Any part of a rope that lies in a compensating sheave.

(f)

Any part of a rope that may be subject to abrasion by external features.

13.7 INTERNAL INSPECTIONS Internal deterioration is the prime cause of many rope failures, mainly due to corrosion and the normal progress of fatigue. A normal external inspection may not reveal the extent of internal deterioration, even to the point where fracture is imminent. Single-layer stranded ropes may be opened up sufficiently to permit an assessment of their internal condition, provided that they are at zero tension; however, some limitations occur with large rope sizes. Permanent damage can be caused to multi-layer wire ropes if they are opened. Internal inspection should always be carried out by a competent person. The method of inspection (see Figure 13.7) consists of firmly attaching two clamping jaws of suitable size at a suitable distance apart to the rope. During the inspection of portions of rope adjacent to terminations, it is sufficient to use a single clamping jaw, since the end anchorage system, or a bar suitably located through the end portion of the termination, may be used as the second clamp. By the application of a force to the clamping jaws in the opposite direction to the rope lay, the outer strands separate and move away from the core. Care should be taken during the opening process to ensure that the clamping jaws do not slip about the periphery of the rope. The strands should not be displaced excessively. When a limited opening is achieved, a small probe, such as a screwdriver, may be used to remove grease or debris that could hinder observation of the interior of the rope. The essential points that should be observed are as follows: (a)

State of the internal lubrication.

(b)

Degree of corrosion.

(c)

Indentation of wires caused by pressure or wear.

(d)

Presence of wire breaks (these are not necessarily visible).

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AS 2759—2004

After inspection, a service dressing should be introduced into the opened part and the clamping jaws rotated with moderate force to ensure correct replacement of the strands around the core. After removal of the jaws, the outer surface of the rope should be greased. Since it is impossible to inspect the interior of the wire rope over the whole of its length, suitable sections shall be selected. For wire ropes that wind onto a drum, or pass over pulleys or rollers, it is recommended that the lengths that engage the pulley grooves when the appliance is in a loaded condition be inspected. Those localized lengths in which shock forces are arrested (i.e., adjacent to drum and jib head pulleys) and those lengths that are particularly exposed to the weather for long periods should be inspected. Attention should be given to the length of rope close to its termination, and this is particularly important for fixed ropes, such as stays or pendants. 13.8 NON-DESTRUCTIVE TESTING Non-destructive testing may be appropriate, to confirm the integrity of a wire rope for its continued use. This testing provides an indication of the loss of metallic area (LMA) and any local faults (LF), such as broken wires.

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NOTE: Refer to AS4812 for NDT of Wire Rope

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AS 2759—2004

SEC TION

RO P E

D I S C ARD

14.1 GENERAL The criteria by which ropes are evaluated and discarded will vary considerably from job to job, and the proper extent and frequency of inspection will depend on possible risk to personnel and equipment, the rate of wear, fatigue, corrosion, rope stretch, reduction in rope diameter, etc. The type and distribution of wire failures or deterioration in a rope are generally a very good indication of their origin.

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The grounds for discarding wire ropes are stated variously in different countries, but normally are restricted to the following: (a)

A maximum percentage loss of breaking strength, and therefore design factor, generally based on the physical tensile testing of the section of the rope or its component wires in certified testing machines. This check is applied in most countries particularly to hoisting and haulage ropes.

(b)

A maximum number of broken or cracked outer wires in the rope.

(c)

A maximum allowable wear on the outer wires in the rope (see also Clause 14.2).

(d)

A maximum percentage loss in effective metallic area in the form of broken or cracked wires plus wear on the outer wires.

(e)

Mechanical damage, or corrosion, or both.

(f)

For some applications, a limit of rope life is set for discard of rope, irrespective of its use.

Each and every one of these grounds for rope discard has its weaknesses, however, and the following remarks should be taken into account. Tensile tests are normally carried out on straight samples, while the ropes in service are normally operated over drums and sheaves, which add the effects of bending and contact stresses within the rope to the tensile stresses resulting from the application of the load to the rope. These tests are carried out at very slow speeds and cannot cater for the effects of impact loading met on many rope applications as a result of sudden acceleration and of sudden braking. Items (b), (c) and (d) above do not take into consideration the fact that the total metallic area of all the outer wires in the rope can vary considerably from one construction to another, and consequently the reserve strength of the remaining inner wires of the rope as well. Non-destructive electromagnetic testing is often carried out on winding and passenger-carrying aerial ropes; however, close visual inspections of rope still remain the most used practical check on rope conditions in service. Length of rope life is seldom a measure of the work done on, or by, a rope. Where possible (particularly on production work), rope life should be measured in terms of tonnes, tonne metres, etc, hoisted or handled, or number of working operations. Many companies, in the interest of guaranteed safety, however, prefer to set a working life for their hoisting, crane, and similar ropes, and then re-allocate such ropes to secondary tasks where risk to life and equipment are not present.

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AS 2759—2004

Figure 14.1 graphically illustrates the normal change of rate of overall deterioration that takes place in an operating rope; as a rule, initially this is very gradual and then increases to the point of discard at a rate governed by the duty, type of equipment, rope construction, number of work cycles, operator skill and care, and so on. All inspections should take account of the individual types of rope deterioration covered by this Section. However, deterioration will frequently result from a combination of factors giving a cumulative effect, which should be recognized by the competent person, and which will reflect on the decision to discard the rope or to allow it to remain in service. 14.2 CONSTRUCTION Table 14.2 gives an indication of some physical characteristics of steel wire ropes, e.g., the outer wire size of a 22 mm 6 × 19 S rope = (0.080 × 22) mm = 1.76 mm. The approximate reserve strength is the breaking force contributed by the inner wires of the rope. TABLE 14.2

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CHARACTERISTICS OF WIRE ROPE 1

Rope construction

Ratio of sizes of outer wire to rope

Approx. reserve strength percent

6 × 7 (6/1) 6 × 10 FS (7/3) 6 × 24 FS (9/12/3) 6 × 19 S (9/9/1) 6 × 25 FS (10/12/3)

0.125 0.110 0.090 0.080 0.083

17 23 31 32 31

9 × 6/6 × 7/3 NR 9 × 6/6 × 12/6 + 6/1/7 × 7 NR 6 × 21 FW (10/5 + 5/1) 6 × 26 WS (10/5 & 5/5/1) 6 × 27 FS (12/12/3)

0.076 0.075 0.073 0.070 0.070

48 54 37 38 34

6 × 19 W (6 & 6/6/1) 17 or 18 × 7 NR (6/1) 6 × 19 (12/6/1) 8 × 19 S (9/9/1) 6 × 25 FW (12/6 + 6/1)

0.077/0.059 0.067 0.065 0.065 0.065

41 46 40 32 45

6 × 31 SW (12/6 & 6/6/1) 6 × 24 (12/12/F) 8 × 21 FW (10/5 + 5/1) 12 × 6/3 × 24 NR 6 × 36 FS (15/12/9)

0.065 0.063 0.057 0.060 0.059

42 34 37 50 44

6 × 29 FW (14/7/7/1) 6 × 36 SW (14/7 & 7/7/1) 6 × 24 (15/9/F) 6 × 26 W (7 & 7/7/4/1) 34 × 7 NR (6/1)

0.058 0.055 0.055 0.064/0.046 0.048

47 50 37 48 59

8 × 25 FW (12/6 + 6/1) 6 × 41 SW (16/8 & 8/8/1) 6 × 49 SW (16/8 & 8/8/8/1) 6 × 37 (18/12/6/1)

0.068 0.050 0.051 0.046

45 55 56 56

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AS 2759—2004

14.3 FRACTURED STRANDS If a complete strand fractures, the rope shall be discarded. 14.4 BROKEN WIRES 14.4.1 Number of wire breaks General purpose ropes, crane ropes and hoist ropes should be discarded whenever any of the types of degradation exceed the limits given in Table 14.4.1, which allows for internal wire breaks and is valid for all constructions of rope. However, the rope life may be ended before these limits are reached. Figure 14.1 shows typical rates of deterioration of wire ropes and how this will vary with different applications. For guidance on the discarding of lift ropes, see AS 1735.2. In 6-strand and in 8-strand ropes, wire breaks occur principally at the external surface (see Figure 14.4.1(A) (a) and (b). This does not apply to wire ropes having a number of layers of strands (typically multi-strand constructions), where the majority of wire breaks occur internally and are therefore non-visible fractures.

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Figures 14.4.1(B) to 14.4.1(H) illustrate ropes with broken wires.

FIGURE 14.1 TYPICAL RATE OF DETERIORATION OF WIRE ROPES

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AS 2759—2004

TABLE 14.4.1 LIMITS OF DEGRADATION FOR DISCARD OF GENERAL LIFTING PURPOSE ROPES, CRANE ROPES AND HOIST ROPES (See Notes 1 and 2) 1

Limit of degradation for discard (see Note 4) Type of degradation

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Broken wires

Construction (see Note 3)

Maximum allowable number of broken wires over a length of 6 times the rope’s diameter

Maximum allowable number of broken wires over a length of 30 times the rope’s diameter

6 × 19 (12/6/1) 6 × 19 S (9/9/1) 6 × 26 SW (10/5 and 5/5/1) 6 × 25 FW (12/6 and 6/1)

5 3 5 5

10 6 10 10

6 × 29 FW (14/7/7/1) 6 × 24 (15/9/F) 8 × 19 S (9/9/1) 8 × 25 FW (12/6 and 6/1)

7 5 5 6

14 10 10 13

6 × 36 SW (14/7 and 7/7/1) 6 × 37 (18/12/6/1) 6 × 41 SW (16/8 and 8/8/1) 18 × 7 NR

7 10 9 1

14 19 18 2

34 × 7 NR 4 × 48

2 2

4 4

Wear

All types

Outer wires are worn more than one-third of their diameter

Loss of area

All types

The loss of metallic area due to visible combined wire wear and broken or cracked wires exceeds 10%

Corrosion

All types

Corrosion is marked by noticeable pitting or loosening of outer wires

NOTES: 1

The number of wire breaks before discard in Table 14.4.1 is quite high, and if wire breaks are concentrated in one strand, lower levels for discard are appropriate. If more than one third of the outer wires in a strand are broken over a length of six times the rope diameter, the rope shall be discarded.

Where ropes are used for lifts, AS 1735.2 applies, which is less stringent than Table 14.4.1. The mining industry frequently requires more stringent discard criteria than Table 14.4.1.

Ropes of Lang’s lay construction other than rotation resistant ropes shall have no more than 50% of the above values.

Number of broken wires alone is not the only factor in discarding a wire rope.

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AS 2759—2004

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(a) Winding rope which has severe wear, corrosion and fatigued broken wires all contributing to the degradation of the rope. Discard immediately

(b) Offshore rotation resistant rope where corrosion has hastened the collapse of rope and its removal from service

FIGURE 14.8(D) MORE EXAMPLES OF CORROSION FROM DIFFERENT APPLICATIONS WHERE CORROSION HAS BEEN JOINED BY OTHER DETERIORATION FACTORS

14.9 WEAR Wear occurs on internal wires and external wires. In both cases it is promoted by lack of lubrication, or incorrect lubrication, and also by the presence of dust and grit. Wear reduces the strength of ropes by reducing the cross-sectional area of the steel. Where the diameter of the rope has diminished to 95% or less of the nominal rope diameter, the rope should be discarded even if no wire breaks are visible. Also, where surface wires are reduced in diameter by more than one third, the rope shall be replaced (see Figure 14.9(c)). Internal wear is caused by friction between individual strands and wire in the rope, particularly where it is subject to bending. External wear is caused by abrasion of the crown wires of outer strands in the rope such as rubbing contact with the grooves in the sheaves and the drums. Examples of external wear are illustrated by Figure 14.9(A). The condition is particularly evident on moving ropes at points of sheave contact while the load is being accelerated or decelerated, and shows itself as flat surfaces on the outer wires. When first put to work, a wire rope will often develop a considerable flat wear on the outer wires, but in fact actual loss of section is only slight. As rope service progresses, the outer wire wearing surface gradually increases and the rate of wear slows down as shown by curve AW in Figure 14.9(B). Where there may be risk to personnel (as on cranes, haulages or mine hoists), it is seldom wise to allow the wear on the outer wires of a rope to exceed one third of their diameter.

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AS 2865—2009

Australian Standard® Confined spaces

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AS 2865—2009 (e)

recognize the need for training of persons whose tasks are associated with confined spaces.

1.3 APPLICATION This Standard is intended for use by designers, manufacturers, suppliers, modifiers and users of confined spaces as defined in Clause 1.5.5. NOTE: The need to prepare a written risk assessment and written authority for entry may be waived only for the duration of an emergency.

The mandatory requirements of this Standard are contained within boxes and printed in bold type. An organization that does not follow the Standard in all respects would still be required to meet the mandatory requirements in the boxes. 1.4 REFERENCED DOCUMENTS A list of referenced and related documents is given in Appendix B. 1.5 DEFINITIONS For the purpose of this Standard, the definitions below apply. 1.5.1 Airborne contaminant Accessed by Wesfarmers Industrial and Safety Ltd on 12 Mar 2018 (Document currency not guaranteed when printed)

Any contaminant present in the air that may be harmful to persons. 1.5.2 Atmospheric monitoring The continuous measurement of oxygen concentration or airborne contaminants over an uninterrupted period of time. 1.5.3 Atmospheric testing The measurement of oxygen concentration or airborne contaminants that is not continuous. 1.5.4 Competent person A person who has, through a combination of training, education and experience, acquired knowledge and skills enabling that person to perform a specified task correctly. 1.5.5 Confined space An enclosed or partially enclosed space that is not intended or designed primarily for human occupancy, within which there is a risk of one or more of the following: (a)

An oxygen concentration outside the safe oxygen range.

(b)

A concentration of airborne contaminant that may cause impairment, loss of consciousness or asphyxiation.

(c)

A concentration of flammable airborne contaminant that may cause injury from fire or explosion.

(d)

Engulfment in a stored free-flowing solid or a rising level of liquid that may cause suffocation or drowning.

NOTES: 1

Enclosed or partially enclosed spaces that may meet the definition criteria for a confined space are— (a)

storage tanks, tank cars, process vessels, boilers, pressure vessels, silos and other tanklike compartments;

(b)

pipes, sewers, shafts, degreaser and sullage pits, ducts and similar structures; and

(c)

any shipboard spaces entered through a small hatchway or entry point, cargo tanks, cellular double bottom tanks, duct keels, ballast and oil tanks, and void spaces.

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AS 2865—2009 2

A confined space may or may not have restricted means of entry and exit. Appropriately sized entry and exit points are important for the safe entry and exit or retrieval of a person(s) in an emergency. However, a restricted means of entry or exit is not a consideration in identifying an enclosed or partially enclosed space as a confined space.

Most enclosed or partially enclosed spaces are intended or designed primarily for human occupancy, e.g. offices and workshops where adequate ventilation and lighting, safe means of access and egress, etc. are provided. From time to time they may have atmospheric hazards produced by task-related activities such as welding. Such task-related hazards are not covered by this Standard and other safety systems apply.

Some enclosed or partially enclosed spaces have atmospheric contaminants that are harmful to persons but are designed for persons to occupy, e.g. abrasive blasting or spray painting booths. Enclosed or partially enclosed spaces that are intended or designed primarily for human occupation and have systems such as gaseous fire extinguishing systems (see AS 4214) or inert gas systems for beverage dispensing (see AS 5034) installed, are not confined spaces. In such cases, other safety systems such as relevant legislation, Standards or Codes of Practice apply.

A rising level of a liquid in an enclosed or partially enclosed space may cause engulfment through the inability of a person to readily exit the space. Drowning in a reservoir, dam or tank where the level of liquid is static is not considered to be drowning from engulfment.

1.5.6 Contaminant

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Any dust, fume, mist, vapour, biological matter, gas or other substance in liquid or solid form, the presence of which may be harmful to persons. 1.5.7 Engulfment The immersion or envelopment of a person by a solid or liquid (e.g. grain, sugar, flour, sand, coal, fertilizer and other substances in a powder or granular form) that is stored within the confined space. 1.5.8 Entry (to a confined space) When a person’s head or upper body is within the boundary of the confined space. NOTE: Inserting an arm for the purpose of atmospheric testing is not considered as entry to a confined space.

1.5.9 Explosive limits

1.5.9.1 Lower explosive limit (LEL) The concentration of a flammable contaminant in air below which the propagation of a flame does not occur on contact with an ignition source.

1.5.9.2 Upper explosive limit (UEL) The concentration of a flammable contaminant in air above which the propagation of a flame does not occur on contact with an ignition source. NOTE: The terms ‘explosive limit’ and ‘flammable limit’ are equivalent. AS/NZS 60079.20 and AS/NZS 61779.1 use the term ‘flammable limit’ whilst other standards use the more widely accepted term ‘explosive limit’.

1.5.10 Exposure standard An airborne concentration of a particular substance in the person’s breathing zone, exposure to which, according to current knowledge, should not cause adverse health effects or undue discomfort to nearly all persons. The exposure standard can be of three forms: Time- weighted average (TWA), short-term exposure limit (STEL) or peak exposure limit.

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AS 2865—2009 1.5.20 Stand-by person A competent person assigned to remain on the outside of, and in close proximity to, the confined space and capable of being in continuous communication with and, if practical, observing those inside. In addition, where necessary, the competent person may operate and monitor equipment for the safety of personnel in the confined space and initiate emergency response. 1.5.21 Supplied-air respirator A device that supplies air to the wearer from a source other than the ambient atmosphere. 1.5.22 Task-related hazard In respect to a confined space, exposure to a hazard because of the task being conducted on or in the confined space. 1.5.23 Written authority A document that gives permission for entry into a confined space and the conduct of tasks associated with the confined space.

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NOTE: The written authority is sometimes known as an ‘entry permit’, ‘access authority’ or ‘permit to work’.

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AS 2865—2009 2.6 TRAINING AND COMPETENCY 2.6.1 Training and competency assessment The requirements for training and assessment of competency are as follows: (a)

All persons with tasks associated with a confined space shall be trained and assessed as competent to conduct those tasks.

(b)

Persons shall be reassessed at appropriate intervals to maintain their competency to conduct tasks associated with confined spaces.

2.6.2 Records of training and competency The training that is provided to persons and the achieved competencies shall be recorded. NOTE: Additional guidance for the provision of training and competency assessment is given in Appendix D.

2.7 RISK MANAGEMENT

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A methodology for the management of risks associated with the confined space should be established and regularly reviewed. This methodology should cover hazard identification, risk assessment and control of risks based on the hazards of the confined space, operational experience, products and services and tasks associated with the confined space. 2.8 CONFINED SPACE EMERGENCIES 2.8.1 Confined space emergency response planning Appropriate emergency response and first aid procedures and provisions shall be identified, planned, established and rehearsed. 2.8.2 Confined space emergency response Those persons involved in an emergency response shall be made aware of the conditions and the number of persons in the confined space prior to any entry. 2.8.3 Confined space emergency procedures In a confined space emergency, the spontaneous reaction to immediately enter and attempt to rescue a person from a confined space could lead to the death or serious injury of those attempting the rescue. All persons who might be involved in any way with emergency response associated with a confined space should be made aware that emergency response procedures are to be followed at all times. 2.9 DOCUMENTATION 2.9.1 General Documentation should be established and maintained in a suitable medium, e.g. in print or electronic form, to at least— (a)

identify external (e.g. legal) and internal organizational requirements;

(b)

assign key roles and responsibilities;

(c)

identify the location of confined spaces in the workplace;

(d)

outline the system for hazard/risk assessments and risk control;

(e)

identify training and competency requirements;

(f)

set out confined space entry requirements (e.g. access authorities, entry permits and permits to work);

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AS 2865—2009 3.2.2 Security and signposting Confined spaces should at all times be secured against unauthorized entry and, where practicable, permanently signposted (see Figure 2). Signs should comply with AS 1319.

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When entry and exit to a confined space is required, signs and barriers shall comply with Clause 3.4.29(f).

FIGURE 2 TYPICAL CONFINED SPACE SIGN

3.3 RISK ASSESSMENT 3.3.1 Conducting a risk assessment A risk assessment shall be conducted by a competent person or persons before conducting any tasks associated with the confined space. The assessment shall be documented and take into account at least the following: (a)

The hazards of the confined space.

(b)

The tasks required to be conducted, including the need to enter the confined space.

(c)

The range of methods by which the tasks can be conducted.

(d)

The hazards involved and associated risks involved with the actual method selected and equipment proposed to be used.

(e)

Emergency response procedures.

(f)

The competence of the persons to conduct the tasks.

3.3.2

Risk factors

Factors to consider when undertaking a risk assessment of a confined space include the following: (a)

Atmospheric assessment, including testing or monitoring to be undertaken and the parameters to be assessed before a written authority is issued.

(b)

Engulfment of a person in any flowing solids in the confined space or engulfment from a rising level of liquid in the confined space.

(c)

All proposed operations and tasks, particularly those that may cause a change to the conditions in the confined space.

(d)

The number of persons occupying the space.

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AS 3569—2010

(Incorporating Amendment No. 1)

Australian Standard® Steel wire ropes—Product specification

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AS 3569—2010

S EC TION

ELEM ENTS

R OP E

2.1 DESCRIPTION 2.1.1 General Figure 1 shows the components of a stranded rope. The system for describing steel wire ropes shall take into account the number of strands, the number of outer strands, the number of layers of strands in the rope and the number of wires, the number of outer wires, the number of layers of wires and strand lay type of the outer strand.

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LEGEND:

1 = Wire rope 2 = Strand 3 = Wire 4 = Core

FIGURE 1

STRANDED ROPE

2.1.2 Direction and type of lay The direction and type of rope lay shall be one of the following: (a)

Right ordinary lay (sZ). NOTE: Formerly referred to as right hand ordinary lay (designated RHOL) and right regular lay (designated RRL).

(b)

Left ordinary lay (zS). NOTE: Formerly referred to as left hand ordinary lay (designated LHOL) and left regular lay (designated LRL).

(c)

Right Lang lay (zZ). NOTE: Formerly referred to as right hand Langs lay (designated RHLL) or right Lang lay (designated RLL).

(d)

Left Lang lay (sS). NOTE: Formerly referred to as left hand Langs lay (designated LHLL) or left Lang lay (designated LLL).

(e)

Right alternate lay (aZ). NOTE: Formerly referred to as right hand alternate lay (designated RHAL).

(f)

Left alternate lay (aS). NOTE: Formerly referred to as left hand alternate lay (designated LHAL). NOTE:The direction and type of rope lay should be specified by the purchaser.

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AS 3569—2010 TABLE 2.2.1.5 TOLERANCES ON ROPE DIAMETER Nominal rope diameter

Tolerance as percentage of nominal diameter

(d)

Ropes with strands that are exclusively of Ropes with strands that wire or incorporate solid polymer centres incorporate fibre centres*

mm 2≤d< 4

+8 0

—

4≤d< 6

+7 0

+9 0

6≤d< 8

+6 0

+8 0

≥8

+5 0

+7 0

* For example, 6 × 24 FC

2.2.2 Difference between diameter measurements

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The difference between any two of the four measurements taken in accordance with Clause 7.3 and expressed as a percentage of the nominal rope diameter shall not exceed the values given in Table 2.2.2. TABLE 2.2.2 PERMISSIBLE DIFFERENCES BETWEEN ANY TWO DIAMETER MEASUREMENTS Nominal rope diameter

Tolerance as percentage of nominal diameter

(d)

Ropes with strands that are exclusively of Ropes with strands that wire or incorporate solid polymer centres incorporate fibre centres*

mm 2≤d< 4 4≤d< 6 6≤d< 8 ≥8

7 6 5 4

— 8 7 6

* For example, 6 × 24 FC

2.2.3 Rope lay length (H) Distance parallel to the longitudinal rope axis in which the outer wires of a spiral rope, the outer strands of a stranded rope or the unit ropes of a cable-laid rope make one complete turn (or helix) about the axis of the rope (see Figure 2.2.3). NOTE: For description of cross-lay, see Clause 2.3.11.

For single-layer ropes of 6 × 7 class, the length of lay (H) of the finished rope shall not exceed 8 × rope diameter (d). For other single-layer ropes with round strands (except those with three or four strands), parallel-lay closed ropes and rotation-resistant ropes with round strands or shaped strands, the length of lay (H) of the finished rope shall not exceed 7.25 × rope diameter (d). For single-layer ropes with shaped strands, (e.g., triangular strand) the length of lay (H) of the finished rope shall not exceed 10 × rope diameter (d).

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AS 3569—2010

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FIGURE 2.2.3 LAY LENGTH—ROPE

2.2.4 Strand lay length (h) Distance parallel to the longitudinal strand axis in which an outer wire makes one complete turn (or helix) about the axis of the strand (see Figure 2.2.4).

FIGURE 2.2.4 LAY LENGTH—STRAND

2.2.5 Rope length

2.2.5.1 Measured rope length (Lm) Length which corresponds to the actual length supplied using a prescribed method. NOTE: The measured length may also be specified at a pre-determined load.

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AS 3569—2010

S EC TION

R OP ES

AND

R OP E

TYPES

3.1 STRANDED ROPE Stranded rope is an assembly of several strands laid helically in one (single-layer rope) or more (rotation-resistant or parallel-closed rope) layers around a core or centre. NOTE: Stranded ropes consisting of three or four outer strands might, or might not, have a core.

3.2 SINGLE-LAYER ROPE

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Single-layer rope is stranded rope consisting of one layer of strands laid helically around a core (see Figure 3.2).

FIGURE 3.2 SINGLE-LAYER STRANDED ROPES—EXAMPLES

3.3 ROTATION-RESISTANT ROPE Stranded rope designed to generate reduced levels of torque and rotation when loaded (see Figure 3.3). Rotation-resistant rope has previously been known as non-rotating or multi-strand rope. NOTES: 1

Rotation-resistant ropes generally comprise an assembly of at least two layers of strands laid helically around a centre, the direction of lay of the outer strands being opposite to that of the underlying layer.

Ropes having three or four strands can also be designed to exhibit rotational-resistant properties.

FIGURE 3.3 ROTATION-RESISTANT ROPES—EXAMPLES

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AS 3569—2010 3.4 PARALLEL-CLOSED ROPE Stranded rope consisting of at least two layers of strands laid helically in one closing operation around a strand or fibre centre (see Figure 3.4).

FIGURE 3.4 PARALLEL-CLOSED ROPE—EXAMPLE

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3.5 COMPACTED STRAND ROPE Stranded rope in which the strands, prior to closing of the rope, are subjected to a compacting process such as drawing, rolling or swaging (see Figure 3.5).

FIGURE 3.5 COMPACTED STRAND ROPE—EXAMPLE

3.6 COMPACTED (SWAGED) ROPE Stranded rope which is subjected to a compacting (usually swaging) process after closing the rope, thus reducing its diameter (see Figure 3.6).

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AS 3569—2010

SEC TION 7 VER IF IC AT ION OF R E Q U I R E M E N T S A N D T ES T M E T H O D S 7.1 MATERIALS Compliance with the wire, core and lubricant requirements shall be confirmed through a visual verification of the inspection documents supplied with the wire, core and lubricant respectively. Where testing of wires taken from the rope is required such testing shall be in accordance with Appendix E. 7.2 ROPE MANUFACTURE Compliance with the requirements for wire joints and preformation shall be confirmed through visual verification. 7.3 TEST ON ROPE FOR DIAMETER

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Rope diameters shall be measured in accordance with Clause 2.2.1. Rope diameters shall comply with the requirements in Clause 2.2.1. 7.4 TEST ON ROPE FOR BREAKING FORCE 7.4.1 Method 1—Measured breaking force (Fm) The method of test and acceptance criteria shall be in accordance with ISO 3108 except for the following: (a)

The selected test piece shall have its ends secured to ensure that the rope does not unravel.

(b)

The minimum free test length, excluding any rope terminations, shall be 600 mm or 30 × nominal rope diameter, whichever is the greater.

(c)

After 80% of the minimum breaking force has been applied, the force shall be increased at a rate of not more than 0.5% of the minimum breaking force per second.

(d)

When the minimum breaking force is reached or exceeded, the test may be terminated without breaking the rope.

(e)

The test may be discounted where the rope fractures within a distance equivalent to six rope diameters from the base of the grip or the termination and the minimum breaking force has not been reached.

(f)

When the minimum breaking force value is not reached, three additional tests may be carried out, one of which shall achieve or exceed the minimum breaking force value.

7.4.2 Method 2—Calculated measured (post-spin) breaking force Add together the measured breaking forces of all the individual wires after they have been removed from the rope and multiply this value by either— (a)

the spinning loss factor derived from Appendix D; or

(b)

the partial spinning loss factor obtained from the results of type testing.

The partial spinning loss factor used in the calculation shall be the lowest of the three values obtained from type testing. In the case of triangular strand ropes, the triangular centre of the strand may be considered as an individual wire.

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AS 3569—2010 The wires shall be tested in accordance with the wire tensile test specified in ISO 6892. When this method (i.e., Method 2) is used for the periodic test (see Table 6.1) and the calculated measured (post-spin) breaking force value is less than the intended minimum breaking force value, another test using Method 1 shall be carried out. NOTE: The result from this test is known as the ‘calculated measured (post-spin) breaking force’.

If the measured (actual) breaking force in this second test fails to meet the intended minimum breaking force value, the minimum breaking force shall be de-rated to a value not exceeding the measured (actual) breaking force value and type testing shall be repeated using Method 1. In such cases, the rope grade shall either be de-rated in line with the de-rated minimum breaking force value or deleted from the rope designation. 7.4.3 Method 3—Calculated measured (pre-spin) breaking force Add together the measured breaking forces of all the individual wires before they are laid into the rope and multiply this value by the total spinning loss factor obtained from the results of type testing. The total spinning loss factor used in the calculation shall be the lowest value of the three values obtained from type testing. The wires shall be tested in accordance with the wire tensile test specified in ISO 6892.

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NOTE: The result from this test is known as the ‘calculated measured (pre-spin) breaking force’.

When this method (i.e., Method 3) is used for the periodic test (see Table 6.1) and the calculated measured (pre-spin) breaking force value is less than the intended minimum breaking force value, another test using Method 1 shall be carried out. If the measured breaking force in this second test fails to meet the intended minimum breaking force value, the minimum breaking force shall be de-rated to a value not exceeding the measured breaking force value and type testing shall be repeated using Method 1. In such cases, the rope grade shall either be de-rated in line with the de-rated minimum breaking force value or deleted from the rope designation. 7.4.4 Breaking force based on component tests For six-strand rope (round or triangular strand) and eight-strand rope having a breaking force in excess of 1500 kN, the following method of test is allowed as an additional alternative to the methods of testing referred to above. Each of the component strands and, if applicable, the wire rope core from a sample of the completed rope is tested and the rope breaking force is calculated from the component strand and core tests as follows: (a)

For wire rope with either six or eight round strands: sum of the test breaking force IWRC test breaking force Rope breaking force = + of each strand × 0.925 × 0.45

(b)

For wire rope with six triangular strands: Rope breaking force =

sum of the test breaking force of each strand × 0.95

IWRC test breaking force × 0.45

The calculated rope breaking force above is considered equivalent to the test breaking force of the complete rope. NOTE: This method of calculation of rope breaking force is not considered appropriate for multi- strand rotation-resistant ropes.

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AS 3569—2010

APPENDIX F

ROPE GRADE EQUIVALENTS (Informative) Table F1 gives guidance on equivalent rope grades. TABLE F1 COMPARISON OF ROPE GRADES—FOR GUIDANCE ONLY Equivalent rope grade (MPa)

1770

EIP

1960

EEIP

2160

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Rope grade designation (American Petroleum Institute)

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AS 3775.1—2014

AS 3775.1:2014

Chain slings for lifting purposes—Grade T(80) and V(100) Part 1: Product specification

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AS 3775.1—2014 4 COMPETENT PERSON REQUIREMENTS 4.1 General Competent persons, shall be suitably trained, qualified by knowledge and practical experience, and with the necessary instruction to correctly assemble and test Grade T(80) and V(100) chain slings. They shall be able to detect and evaluate defects and weaknesses that may affect the intended performance of the equipment and carry out work as specified in this Standard. 4.2 Competency standards and procedures Competency standards and procedures shall include the requirements of this Standard. The verification of such competency standards shall incorporate an established competency based training course and records shall be maintained. 4.3 Visual acuity The competent person shall have satisfactory near and medium range vision. The visual acuity of a competent person shall be tested periodically, with a maximum duration of 2 years between each test, by an optometrist or suitably trained person. The competent person shall be able to demonstrate clear near vision. Near vision acuity (Jaeger No. 1) shall permit reading a minimum of Times Roman 4.5 points vertical height at not less than 300 mm with one or both eyes, either corrected or uncorrected. Accessed by Wesfarmers Industrial and Safety Ltd on 27 Apr 2018 (Document currency not guaranteed when printed)

NOTE: AS 3978 gives guidance on visual acuity for visual inspections.

5 DESIGN AND MANUFACTURE 5.1 Chain Chain shall be Grade T(80) or V(100) chain complying with AS 2321 or other equivalent recognized International Standard. 5.2 Lifting components Any lifting components shall comply with AS 3776 or other established Standards for a lifting device or lifting tackle. 5.3 Sling hooks with latch (catch) Each hook with a latch shall comply with AS 3776 and shall have a spring-loaded or positive latch (catch) to ensure that the load cannot become accidentally unhooked. 5.4 Hooks without latch (catch) Hooks without a latch are generally used for specific application, i.e. non-general use. Where there is a risk of the hook becoming detached during use, a risk assessment shall be conducted. The chain sling shall be tagged to identify the specific application. NOTE: Guidance on implementing a risk assessment is given in AS/NZS ISO 31000.

5.5 Grades Grades T(80) chain slings should be made with Grade T(80) chain and components. Grade V(100) chain slings should be made with Grade V(100) chain and components. 5.6 Using components of different grades Grade T(80) chain components or chain may be used with Grade V(100) components provided the components are compatible and the sling assembly is rated to the lowest rated component for load and temperature. Grade V(100) chain components or chain may be used on Grade T(80) slings provided the components are compatible and the sling assembly is rated to the lowest rated component for load and temperature. All chain in multi-leg chain assemblies shall be the same Grade.

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AS 3775.1—2014 5.7 Compatibility All components of a chain sling assembly shall be compatible. Chain and component assembly compatibility shall be assessed by a competent person to ensure free articulation, axial loading and suitability for purpose is achieved. Where several different grades of material are used for lifting equipment, which results in slings, crane hooks, shackles, and other lifting components varying considerably in size for a given capacity, care shall be taken to ensure the compatibility of the ancillary equipment used to sling the load, both in size and capacity. An intermediate link or shackle may be required to allow for a suitable compatibility between components. The sling assembly shall be rated to the lowest rated component. NOTE: Incompatibility of different types of components may lead to failure. This is particularly relevant to shortening clutches, grab hooks and pins. Verification of compatibility may be obtainable from the suppliers and the designer of any other equipment to be used.

5.8 Typical chain sling configurations Typical chain sling configurations are given in Figures 2 and 3.

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Upper terminal l ink or master l ink

Mechanical joining device

WLL tag Chain

Mechanical joining device Sling hook or other terminal fitting

FIGURE 2 TYPICAL SINGLE-LEG SLINGS WITH MECHANICAL JOINING DEVICES

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AS 3775.1—2014

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Ef fective length

(a) Single- leg sling

Ef fective length

( b) Single- leg reevable sling

Ma x. 60 °

Ef fective length

(d) Two- leg basket sling

FIGURE 3 (in part) TYPICAL CHAIN SLING CONFIGURATIONS

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AS 3775.1—2014

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Ef fective length

(e) Adjustable two- leg sling

Ef fective length

(f ) Adjustable two- leg sling

Ef fective length

(g) Three- leg sling

( h) Four- leg sling

FIGURE 3 (in part) TYPICAL CHAIN SLING CONFIGURATIONS

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AS 3775.1—2014 5.9 Tolerance of length of legs When constructing a multi-leg sling, the difference between the longest and shortest legs which are nominally the same length shall, when measured under equivalent tension, be no more than 10 mm for lengths up to 2 m and 5 mm/m for lengths over 2 m. NOTES: 1

The actual length of each sling should be not less than that ordered and should not exceed that ordered by more than two link pitches (refer AS 2321).

Each leg of a multi-leg sling should consist of the same number of links as each of the other legs. Specific applications may require legs to contain a different number of links.

Upper terminal link Metal tag (see Clause 7.1)

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Intermediate l ink

Joining device

Ef fective length of sling (when hanging freely unloaded)

Chain Leg length

Joining d evice

Sling hook or other terminal f i t ting

FIGURE 4 LENGTHS OF A SLING AND ITS LEGS

5.10 Surface finish The surface finish of the sling shall be one of the following: (a)

Self-colour (see Clause 3.8).

(b)

Painted coating, or other surface finish applied by the manufacturer or in compliance with the instructions of the manufacturer.

For surface finishes that reduce the ultimate tensile strength of the product, the WLL shall be de-rated by the manufacturer to retain the specified design factor.

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AS 3775.1—2014 5.11 Articulation Components shall allow for sufficient articulation to ensure the load will be transmitted axially. 5.12 Lifting component connections The chain assembly shall be such that it will prevent any unintentional disconnection of any of its component parts. A satisfactory pin retention method shall be provided for any load pin, which shall withstand failure of the clevis component under test loading conditions. The system shall not be easily disassembled. No part of the locking devices, including load pins and load pin retention devices, shall protrude beyond the body of the clevis. (See Figure 5).

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Load pin

Retention pin

(a) Radially located retention pin Load pin

Retention pin

(b) ) Tangentially located retention pin

FIGURE 5 TYPICAL LOAD PIN RETENTION FOR CLEVIS

5.13 Number of direct connections

5.13.1

Links

Each upper terminal link and each intermediate link shall not carry more than two load-bearing components to avoid overcrowding and ensure the load will be transmitted axially. Refer to Figure 6 for an example of overcrowding. NOTE: Where more than two load-bearing components are used, the link may become overcrowded inducing additional stresses.

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AS 3775.1—2014 LOAD

Correct

Incorrect

LOAD (a)

(b)

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LOAD

Incorrect

LOAD

(d) Leg sling incorrectly assembled and loaded

FIGURE 7 LOADING OF CONNECTORS

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AS 3775.1—2014 5.13.3 Chain shortening devices Shortening grab hooks and clutches shall not be used for back hooking to create a basket sling off a single joining device. See Figure 8(c). No more than one load-bearing component attached to one side of a joining device shall be used unless specifically designed to do so by the manufacturer of the joining device. See Figure 8(a) and (b). A1

There shall be no basket hitching to a shortening device unless specifically so designed by the component manufacturer. To create a basket sling using shorteners (see Figure 8(d)) where two connectors are load bearing. The master link shall have capacity for the working load limit.

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NOTE: Serious incidents have occurred from the failure of the joining device by misuse of shortening grab hooks inducing side loading. By having the shortening grab hook on a separate joining device, the potential for human error is reduced, however in some applications this may not be possible, e.g. height constraints, overcrowding of intermediate link.

Load bearing Non-load bearing Load bearing

(a)

) Preferred*

Non-load bearing

Load bearing

( b) Alternative*

(d) Correct

* It is preferable for no more than one load-bearing device to be attached to one side of a joining device. See Clause 5.13. However where large size chain is used or when multi-leg chain slings are required the alternative (b) may be required to ensure loads are transmitted axially and weight is reduced for manual handling.

FIGURE 8

CONNECTING LINKS WHERE SHORTENING DEVICES ARE USED

The shortening device should be an integral part of the sling assembly. Where the shortening device is not an integral part of the sling assembly the following shall apply: (a)

The inline shortening sling assembly shall be tested and tagged

(b)

Locking shorteners shall be used for sizes up to 16 mm chain. Refer to Figure 9.

(c)

For chain sizes above 16 mm where the inline shortening sling assembly is not locked to the lifting sling assembly additional measures shall be taken based on a risk assessment, to prevent the risk of injury should it become detached from the sling assembly while suspended. Refer Figure 9. A warning advice to this effect shall accompany those inline slings without locking mechanisms.

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AS 3775.1—2014

Locking mechanism Inline shor tening slings assembly

Locking mechanism

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(a)

( b)

Load bearing

Non-loading bearing

(c)

FIGURE 9 CHAIN ASSEMBLY WITH TYPICAL INLINE SHORTENING SLINGS

5.14 Inline shortening sling Inline shortening slings shall be manufactured, proof loaded and tagged in accordance with this Standard. Refer to Figures 9(a) and 9(b). 5.15 Inline locking shortener A preferred method for inline shortening of chain slings. Refer Figure 9(c). 6 MECHANICAL PROPERTIES 6.1 Strength of sling legs Each single leg of a sling shall be capable of supporting a minimum breaking test force as specified in Appendix D under the conditions specified in Appendix E.

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AS 3775.1—2014 6.2 Strength of upper terminal links and intermediate links of multi-leg slings Each upper terminal link and each intermediate link of multi-leg slings shall be capable of supporting a test force of the chain minimum break force, as specified in Appendix D . NOTE: The factor 1.73 represents multi-leg sling loading at 60° as calculated in Columns 6 and 7 of Tables D1 and D2.

7 MARKING 7.1 General Chain slings shall be permanently and legibly marked with the information required by Clause 7.2 on a durable tag attached to either the upper terminal link or to a link closer to it in a manner that will prevent unintentional disconnection. NOTE: Typical tags are shown in Figure 10.

7.2 Information

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The following information shall be marked on the tag: (a)

WLL, including the different supporting arrangements.

(b)

Conditions of use.

(c)

Identification marking to correlate the sling assembly to the test certificate.

(d)

Identification of the sling manufacturer or sling assembler.

(e)

Grade.

(f)

If required, any appropriate warnings, e.g. use of hooks without latches. Refer to Clause 5.4.

(g)

Date of test. (This is NEW)

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AS 3775.1—2014 A1

General use Application

Grade T (80) Chain Size Date

WLL in Tonnes

No. of Legs

WLL in Tonnes at 60°

90°

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120°

ID.

(a) Front

( b) Back

FIGURE 10 TYPICAL MARKING FOR TAG

8 PROOF TESTING 8.1 Proof loading One or more of the following shall apply: (a)

Each single-leg sling and each sling leg of a multi-leg sling shall be subjected to a proof force that is not less than [(WLL in tonnes) × 9.81 × 2] kN applied under the conditions specified in Appendix D and examined by a competent person. Each multi-upper-terminal link and each intermediate link of a multi-leg sling shall be subjected to a proof force of [(WLL for a single leg in tonnes as specified by Table D1 or D2) × 9.81 × 1.73 × 2] kN. NOTE: The factor 1.73 represents multi-leg sling loading at 60° as calculated in Columns 6 and 7 of Table D1 and D2.

Regardless of any modified WLL, the proof load test force shall be in accordance Tables D1 or D2.

with

(b)

Proof testing of an assembly with mixed grades of components shall be proof tested to the lowest rated component.

(c)

Where all of the components of a sling have been proof tested, but any component has been subjected to further manufacturing or modification subsequent to any earlier proof testing, the completed sling shall be subjected to further proof testing and examined by a competent person.

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AS 3775.1—2014 (d)

Assembled slings shall be proof tested and shall be visually examined by a competent person. Adequate records shall be maintained.

(e)

Slings that have had damaged load-bearing components replaced shall be proof tested.

(f)

Slings with missing tags shall be inspected by a competent person to ensure integrity and identification of components and shall be proof tested and re-tagged.

8.2 Requirements The sling shall— (a)

withstand the application of the proof force, without sustaining damage that may affect its intended function; and

(b)

after testing, be free from any deleterious permanent set or visible defects. (Refer AS 2321 and AS 3776.)

A competent person (see Clauses 3.2 and 4) shall be satisfied that these requirements have been complied with. 8.3 Test certificate

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The proof testing shall be recorded on a test certificate, which shall bear the following information: (a)

Description.

(b)

Grade of chain sling.

(c)

Configuration of sling.

(d)

Nominal size.

(e)

Effective length or leg length.

(f)

Surface finish.

(g)

WLL, general or specific.

(h)

Proof forces.

(i)

Date of proof test.

(j)

Number tested.

(k)

Identification marking correlating with the slings.

(l)

A declaration that the slings comply with this Standard.

(m)

The name of the manufacturer or supplier.

(n)

The name and address of the testing establishment.

(o)

The name of the signatory.

(p)

Type of certificate (e.g. NATA, certifying authority, supplier).

NOTE: The manufacturer or supplier should retain the test certificate for not less than 10 years.

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AS 3775.1—2014

APPENDIX D

SLING WORKING LOAD LIMITS (WLL) AND TEST FORCES (Normative) TABLE D1 MINIMUM WORKING LOAD LIMITS AND TEST FORCES [Grade T(80)] 1

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Master and intermediate links (2, 3 and 4 legs), WLL

Single-leg master link and components Chain size

WLL

Proof force

Breaking force

WLL (see Note 3)

Proof force

Breaking force

6 7 8

1.1 1.5 2.0

21.6 29.4 39.2

43.2 58.9 78.5

1.9 2.6 3.5

37.3 51.0 68.7

74.6 102 137

10 13 16

3.2 5.3 8.0

62.8 104 157

126 208 314

5.5 9.2 13.8

108 181 271

216 361 542

19 20 22

11.2 12.5 15.0

220 245 294

439 491 589

19.4 21.6 26.0

381 424 510

761 848 1020

26 32

21.2 31.5

416 618

832 1236

36.7 54.5

720 1069

1440 2139

NOTES: 1

The proof force is two times WLL [see Clause 8.1(a)].

The breaking force shall be a minimum of four times WLL.

WLL for multi-leg slings is rated for sling angles at 60°, i.e. 1 leg WLL × 1.73.

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AS 3775.1—2014 TABLE D2

MINIMUM WORKING LOAD LIMITS AND TEST FORCES [Grade V(100)] 1

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Master and intermediate links (2, 3 and 4 legs)

Single-leg master link and components Chain size

WLL

Proof force

Breaking force

WLL (see Note 3)

Proof force

Breaking force

4 5 6

0.63 1.0 1.4

12.4 19.6 27.5

24.7 39.2 54.9

1.1 1.7 2.4

21.6 33.4 47.1

43.2 66.7 94.2

7 8 10

1.9 2.5 4.0

37.3 49.1 78.5

74.6 98.1 157

3.3 4.3 6.9

64.7 84.4 135

129 169 271

13 16 18

6.7 10 12.5

131 196 245

263 392 491

11.6 17.3 21.6

228 339 424

455 679 848

19 20 22

14 16 19

275 314 373

549 628 746

24.2 27.7 32.9

475 543 645

950 1087 1291

23 26 28

21 26.5 31.5

412 520 618

824 1040 1236

36.3 45.8 54.5

712 899 1069

1424 1797 2139

785

1570

69.2

1358

2715

NOTES: 1

The proof force is two times WLL [see Clause 8.1(a)].

The breaking force shall be a minimum of a four times WLL.

WLL for multi-leg slings is rated for sling angles at 60°, i.e. 1 leg WLL × 1.73.

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AS 3775.2:2014

Chain slings for lifting purposes—Grade T(80) and V(100) Part 2: Care and use

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(vi)

The determination of WLL.

(vii) Protection of the chain sling from sharp corners of the load using packing material as appropriate to prevent bending or damage to the chain links and/or load shall be used wherever practical. (viii) That the site where the load is to be landed, is prepared in advance of the lifting operation. (ix) (e)

Taking into account environment conditions such as temperature and corrosive atmospheres etc.

Ability to identify the hazards associated with the task and apply controls that will mitigate the risk.

4.3 Inspection of chain slings

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A competent person shall be suitably trained, qualified by knowledge and practical experience to be competent to interpret and implement the requirements of Clause 9 covering the following: (a)

Periodic inspections.

(b)

Defects requiring withdrawal from service.

(c)

Discard criteria.

For repairs, the person shall be competent to interpret and implement the requirements of Clause 10. 4.4 Competency standards and procedures Competency standards and procedures relating to the respective role and duties of competent persons shall include the requirements of this Standard. They shall incorporate an established competency-based training course. Documentation of competency standards and procedures shall be maintained. 4.5 Visual acuity The competent person shall have satisfactory near and medium range vision. The visual acuity of a competent person shall be tested periodically, with a maximum duration of 2 years between each test, by an optometrist or suitably trained person. The competent person shall be able to demonstrate clear near vision. Near vision acuity (Jaeger No. 1) shall permit reading a minimum of Times Roman 4.5 points vertical height at not less than 300 mm with one or both eyes, either corrected or uncorrected. NOTE: AS 3978 gives guidance on visual acuity for visual inspections.

5 STORAGE AND HANDLING Chain slings should be stored on a properly designed rack, such as an A-frame or wall rack. They should not be left lying on the ground after use, where they could be damaged or lost. Users shall ensure the following minimum precautions are applied: (a)

Never heat or heat-treat chain.

(b)

Lightly oil chain prior to prolonged storage.

(c)

Store chain in clean, dry, non-corrosive places.

(d)

Protect from any weld spatter and arc strikes.

(e)

Care shall be taken with chain slings which are left on crane hooks to ensure that they do not present a danger to persons or property and do not become accidently engaged.

NOTE: When being handled, chain slings should not be dropped or thrown down and when being transported they should not be dragged across the floor surface.

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6 SELECTION 6.1 Planning The slinging and lifting operation shall be planned by a competent person (refer to Clause 4.1), before any attempt is made to sling the load. Planning shall include the following considerations: (a)

Assessing the mass of the load to be lifted. Care shall be taken not to underestimate this mass. If there is any doubt about the mass of the load, the lift shall not proceed.

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NOTE: A risk assessment may result in the use of a calibrated load cell to verify the mass to be lifted.

(b)

Ensuring that the load itself, including any lifting points and other lifting devices, will withstand the lifting operation. Refer to Clause 3.4. Care shall be taken for non-axial lifts as derations may apply. Refer to AS 2317 for eyebolts.

(c)

Ensuring that the lifting machine or lifting appliance is rated to lift the load.

(d)

Selecting a suitable sling, taking into account the following:

(e)

(i)

The geometry of the sling, that is, the number of legs, the angles of each leg to the vertical and the disposition of the legs in plan view.

(ii)

The shape of the load and the load distribution on the sling legs. Uneven loading may cause a reduction of the lifting capacity of the sling. It may also cause instability and tilting of the load.

(iii)

The manner in which the load is attached (i.e. straight, reeved or basket configuration). Consider the angle in the reeving and the derating effect due to the higher stresses caused by reeving on the links of the chain.

(iv)

The determination of WLL as prescribed in Clause 7.

Preparing the site where the load is to be landed, in advance of the lifting operation.

6.2 Specification Grade T(80) and Grade V(100) chain slings shall comply with AS 3775.1. NOTE: For typical chain sling configurations, see Appendix B.

A single sling or an arrangement of multiple slings with a WLL that is less than the mass of the load shall not be used. The WLL for chain slings is specified in Clause 7, and Tables 1 and 2. 6.3 Compatibility Several different grades of material are used for lifting equipment, which results in slings, crane hooks, shackles, and other lifting components varying considerably in size for a given capacity. Care shall be taken to ensure the compatibility of the ancillary equipment used to sling the load, both in size and capacity. An intermediate link or shackle may be required to allow for a suitable compatibility between components. NOTES: 1

Commonly used chain assemblies are illustrated in Appendix B. Other special assemblies may be devised for lifting specific unusually shaped loads.

Incompatibility of different types of components may lead to failure. This is particularly relevant to shortening clutches, grab hooks, pins. Verification of compatibility may be obtainable from the suppliers and the designer of any other equipment to be used.

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6.4 Assembly configuration and limitation of use

6.4.1 General Each upper terminal link and each intermediate link shall not carry more than two load- bearing components. Where more than one component is connected by the one connecting link, care should be taken while constructing the sling to avoid overcrowding of components. Overcrowding is considered to occur where an angle of 60° cannot be accommodated. See Figure 1(a). Each end of each joining device shall not have in use more than one load bearing component, unless specifically designed to do so by the manufacturer of the joining device. See Figure 1(b).

Correct

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Incorrect

(a)

( b)

FIGURE 1 OVERCROWDING AND LOAD BEARING

6.4.2 Loading of connecting links Each end of each connecting link shall not have in use more than one load bearing component, unless specially designed to do so by the manufacturer of the connecting links. See Figure 2 (a) to (f).

6.4.3 Application of shortening clutches and shortening hooks Slings may be fitted with shortening devices, to adjust the length of the sling legs. See Figure 3.

6.4.4 Loading of connecting links to form a basket sling Figure 4 illustrates the loading of connecting links to form a basket sling.

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LOAD

Incorrect

Correct

Incorrect

LOAD LOAD

(a)

(b)

(c)

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LOAD

Incorrect

LOAD

(d)

(e)

(f )

FIGURE 2 LOADING OF CONNECTING LINKS

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Non-load bearing

Non-load bearing Load bearing

Load bearing

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(a)

) Preferred*

( b) Alternative*

(d) Correct

* It is preferable for no more than one load-bearing device to be attached to one side of a joining device. See Clause 6.4.3. However where large size chain is used or when multi-leg chain slings are required the alternative (b) may be required to ensure loads are transmitted axially and weight is reduced for manual handling.

FIGURE 3

CONNECTING LINKS WHERE SHORTENING DEVICES ARE USED

Correct

(a)

Incorrect

( b)

FIGURE 4 LOADING OF CONNECTING LINKS TO FORM A BASKET SLING

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6.4.5 Sling modifications Sling legs for general use shall not be lengthened (e.g. by use of a connector). Sling legs may be shortened, provided— (a)

they are inspected by a competent person (see Clauses 3.3 and 4) to ensure integrity;

(b)

in a multi-leg sling, the resultant lengths of the sling legs are equal, unless specified otherwise;

(c)

the added chain and components comply with the Standards to which they have been manufactured; and

(d)

after completion of the assembly, the entire sling is proof tested.

7 DETERMINATION OF WORKING LOAD LIMIT 7.1 General purpose conditions of use General purpose conditions of use are equivalent to a group classification of crane mechanisms of M3 as specified in AS 1418.1. The WLL for a chain sling under general purpose conditions of use shall comply with Tables 1 and 2 and the following, as appropriate: Accessed by Wesfarmers Industrial and Safety Ltd on 04 Jul 2018 (Document currency not guaranteed when printed)

(a)

Where a sling leg is made into a basket hitch by returning the hook to the upper terminal link, the WLL for the upper terminal link shall be sufficient for such an application, i.e. 1.3 times the WLL of the chain [see Figure 6(a)].

(b)

Basket slings The WLL for a basket sling shall be not more than 1.3 times the WLL for the chain. The included angle of a single-leg basket sling shall not exceed 60°.

Adjustable slings The WLL for an adjustable sling shall be as follows: (i)

Where a special purpose hook (e.g. a shortening clutch or grab hook, see Note 3 below) that fully supports the chain link and attains a 100% efficiency is used, the WLL shall be not more than the WLL for the chain to which it is attached.

(ii)

Where Item (i) does not apply, the WLL shall be not more than 0.75 times the WLL for the chain to which it is attached.

(c)

Reeved slings The WLL for a reeved sling shall be not more than 0.75 times the WLL for the chain used for the sling (see Figure 7).

(d)

Non-vertically oriented leg of a sling The WLL for a non-vertically oriented leg of a sling shall allow for its inclination to the vertical.

(e)

Multi-leg slings: (i)

The WLL for a multi-leg sling assembly with more than two legs shall not exceed that for the sling with only two of its legs used with an included angle of 60° between these two legs. That is, the WLL of multi-leg slings comprising more than two legs shall be not more than the WLL for the sling used as a two- leg sling.

(ii)

The maximum included angle for a multi-leg basket sling assembly, or a multileg reeved assembly shall not exceed 60° between the legs (see Figure 12).

(iii)

The largest included angle between any two legs, at the apex, shall be the basis for calculations determining the WLL of a multi-leg sling with more than two legs. See Figure 5 below.

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AS 3775.2:2014

TABLE 1 WORKING LOAD LIMIT (GRADE T)* Working load limit under general conditions of use, t Chain size mm

Single leg slings

Slings of 2, 3 or 4 legs

2 leg slings

ma x. 60 °

Ø (mm)

ma x. 60 °

Straight sling or adjustable sling with no deration

Adjustable sling with deration see Note 1

Reeved sling

0.75

1.1

0.8

1.5

Basket sling Max 60°

Straight sling see Note 2

Reeved sling see Notes 2 and 3

Basket sling see Notes 2, 3 and 4

90°

120°

Max angle 60°

1.3

1.73

1.41

1.3

2.25

0.8

1.4

1.9

1.6

1.1

1.4

2.5

1.1

2.6

2.1

1.5

3.4

1.5

2.6

3.5

2.8

2.6

4.5

3.2

2.4

4.2

5.5

4.5

3.2

4.2

7.2

5.3

4.0

6.9

9.2

7.5

5.3

6.9

11.9

6.0

10.4

13.8

11.3

10.4

18.0

11.2

8.4

14.6

19.4

15.8

11.2

14.6

25.2

12.5

9.4

16.3

21.6

17.6

12.5

16.3

28.1

11.3

19.5

26.0

21.2

19.5

33.8

21.2

15.9

27.6

36.7

29.9

21.2

27.6

47.7

31.5

23.6

54.5

44.4

31.5

70.9

Loading factors

60°

Chain size, mm A1

www.standards.org.au

Bullivants | Page 399 of 692

NOTES TO TABLE 1: Some shortening devices, such as grab hooks, derate the WLL for the sling by 25%. Other shortening devices such as shortening hooks and grab hooks with cradle configuration, may not derate the WLL for the sling. Advice regarding the appropriate deration should be sought by the manufacturer.

The determination of the angle of the multi-leg sling is the largest included angle at the apex of the configuration.

Reeved slings and basket slings, in a two leg configuration have a maximum angle for use of 60°.

To ensure that an appropriately rated master link is used for the 2 leg basket sling, the master link to be used shall be a master link of an appropriate WLL and with intermediate links. This ensures that the factor of 2.25 can be accommodated and that there is no overcrowding with back hooking.

For engineered lifts, refer to Clause 7.2.2.

The WLLs of Grade T(80) chain in the table above is based on nominal dimensions. Some manufacturers may have higher WLLs.

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Bullivants | Page 400 of 692

AS 3775.2:2014

TABLE 2 WORKING LOAD LIMIT (GRADE V)* Working load limit under general conditions of use, t Chain size mm

Single leg slings

Slings of 2, 3 or 4 legs

2 leg slings

ma x. 60 °

Ø (mm)

ma x. 60 °

Straight sling or adjustable sling with no deration

Adjustable sling with deration see Note 1

Reeved sling

0.75

0.63

0.5

0.8

1.4

7 8

Basket sling Max 60°

Straight sling see Note 2

Reeved sling see Notes 2 & 3

Basket sling see Notes 2, 3 & 4

60°

90°

120°

Max angle 60°

1.3

1.73

1.41

1.3

2.25

0.5

0.8

1.1

0.9

0.63

0.8

1.4

0.8

1.3

1.7

1.4

1.3

2.3

1.1

1.8

2.4

2.0

1.4

1.8

3.2

1.9

1.4

2.5

3.3

2.7

1.9

2.5

4.3

2.5

1.9

3.3

4.3

3.5

2.5

3.3

5.6

3.0

5.2

6.9

5.6

5.2

9.0

6.7

5.0

8.7

11.6

9.4

6.7

8.7

15.1

7.5

13.0

17.3

14.1

13.0

22.5

12.5

9.4

16.3

21.6

17.6

12.5

16.3

28.1

10.5

18.2

24.2

19.7

18.2

31.5

12.0

20.8

27.7

22.6

20.8

36.0

Loading factors Chain size, mm

rds.org.au

14.3

24.7

32.9

26.8

24.7

42.8

15.8

27.3

36.3

29.6

27.3

47.3

26.5

19.9

34.5

45.8

37.4

26.5

34.5

59.6

31.5

23.6

41.0

54.5

44.4

31.5

41.0

70.9

30.0

52.0

69.2

56.4

52.0

90.0

w w w .s ta n d a

Bullivants | Page 401 of 692

NOTES TO TABLE 2: Some shortening devices, such as grab hooks, derate the WLL for the sling by 25%. Other shortening devices such as shortening hooks and grab hooks with cradle configuration, may not derate the WLL for the sling. Advice regarding the appropriate deration should be sought by the manufacturer.

The determination of the angle of the multi-leg sling is the largest included angle at the apex of the configuration.

Reeved slings and basket slings in a two leg configuration have a maximum angle for use of 60°.

For engineered lifts, refer to Clause 7.2.2.

The WLLs of Grade V(100) chain in the table above is based on nominal dimensions. Some manufacturers may have higher WLLs.

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Bullivants | Page 402 of 692

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ma x. 60 °

max. 60°

Correct

NOTE: Ensure that WLL of the upper ter minal l in k equals at least 1. 3 t imes the WLL of the chain.

NOTE: See Fig ure 17 for example of application

(a) Single leg sling in basket hitch hooked back to upper terminal link

(b) ) Two leg sling back hooking to intermediate l inks of a master l ink assembly to demonstrate four loading bearing points

Correct

Incorrect

FIGURE 6 BASKET SLINGS

Bullivants | Page 403 of 692

ma x. 60 °

FIGURE 13 TWO-LEG DOUBLE WRAP CHOKE HITCH Accessed by Wesfarmers Industrial and Safety Ltd on 04 Jul 2018 (Document currency not guaranteed when printed)

8.6.3 Requirements and recommendations To avoid dangerous lifting practices and in-service damage, the following conditions apply: (a)

Ensure the upper terminal fitting is compatible with the crane hook or lifting point. The upper terminal link or lifting point of the sling shall be seated in the bowl of the crane hook, never on the point nor wedged in the throat. The crane hook or lifting point should be free to align in any direction, to avoid deformation of any lifting fitting. Safety catches on hooks shall be free to operate.

(b)

When attaching the hook of a sling leg to a load, the load on the hook shall be directed into the bowl of the hook. There shall not be a point loading on hooks. After attachment, any safety latch or self-locking mechanism shall be operational. Hooks without a latch are generally used for specific applications, i.e. non-general use. Where safety latches are not present, a risk assessment shall be conducted. The chain sling shall be tagged to identify the specific application. NOTE: AS/NZS ISO 31000 provides guidance on risk management.

(c)

Chain components shall allow for sufficient articulation to ensure that, when loaded, the load can be transmitted axially. Chain shall never be loaded when twisted or knotted.

(d)

Never reposition chain sling by hammering, either to balance the load or, in the case of a reeved sling, to tighten the bight. See Figure 14. When using a reeved sling, the bight should be allowed to assume its own position (see Figure 7).

(e)

Slings incorporating shortening hooks or clutches shall be used in the correct manner. The load bearing chain shall lead out from the bottom of the hook or clutch (see Figure 3).

(f)

Where grab hooks are used as shortening device, the manufacturer’s recommendations shall be followed, as some types of grab hook without a cradle require the application of a reduced WLL.

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(g)

The shortening device should be an integral part of the sling assembly. Where the shortening device is not an integral part of the sling assembly the following shall apply: (i)

The inline shortening sling assembly shall be tested and tagged

(ii)

Locking shorteners shall be used for sizes up to 16 mm chain. Refer to Figure 15.

(iii)

For chain sizes above 16 mm where the inline shortening sling assembly is not locked to the lifting sling assembly additional measures shall be taken based on a risk assessment, to prevent the risk of injury should it become detached from the sling assembly while suspended. Refer to Figure 15. Warning advice to this effect should accompany those inline slings without locking mechanisms.

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Correct

Incorrect

Never hammer a chain to straighten the l inks or to force the links into position

(a)

( b)

FIGURE 14 REEVED SLINGS

Bullivants | Page 405 of 692

Locking mechanism Inline shor tening slings assembly

Locking mechanism

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(a)

( b)

Load bearing

Non-loading bearing

(c)

FIGURE 15 CORRECT USE OF TYPICAL SHORTENING DEVICES [Refer to Clause 8.6.3(g)]

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8.7 Lifting the load

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The following requirements and recommendations apply to lifting: (a)

Care shall be taken to ensure the load remains stable throughout the lift. A load will be stable, without swinging, if the sling is arranged so that its lifting point is located directly above the centre of gravity. Where this is not possible, extra care shall be given to the selection of suitable slings and their attachment to the load. The sling shall be properly secured to the load, preferably positively attached.

(b)

Hands and other parts of the body should be kept away from the chain to prevent injury, as the slack is taken up. Commence lifting slowly, gradually taking up the slack, until the chain is taught. The load should be raised slightly and a check made that it is secure and assumes the position intended. This is especially important with basket or other loose hitches where friction retains the load.

(c)

A trial lift should be made, prior to the full operation. If the load is not balanced, it should be lowered and the slings repositioned or adjusted using shortening devices.

(d)

In order to prevent dangerous swaying of the load and to position it for landing, a tag line(s) attached to the load is recommended. In no case shall the tag line be attached to the chain sling. No person shall stand or extend any part of their body under the load or within the swing radius or fall zone.

(e)

Chain slings shall not be subject to shock loading. When loads are accelerated or decelerated suddenly, high dynamic forces occur, which increase stresses in the chain. Such situations arise from snatch or shock loading (e.g. from not taking up the slack chain before starting to lift or by the impact of arresting falling loads).

(f)

When landing, avoid the possibility of crushing or trapping the sling, by ensuring the load does not land on the sling. Suitable dunnage should be used to enable the sling to be readily removed by hand.

9 INSPECTION 9.1 In-service Prior to each use, chain slings shall be visually inspected by a competent person. The inspection shall determine whether slings are free of any damage or wear that exceeds the allowable discard criteria (see Clause 9.3) and a WLL tag is fitted. If any defects are detected, the sling shall immediately be withdrawn from service. 9.2 Periodic Slings shall be periodically inspected by a competent person. NOTE: Appendix C provides a guide to periodic inspection.

The following requirements and recommendations apply: (a)

Sling inspections shall be able to identify grade and specification of each component.

(b)

Sling inspections shall be undertaken in an adequately lit location.

(c)

Where necessary, the sling should be cleaned before it is inspected.

(d)

Every individual chain link shall be inspected for any signs of wear, nicks, cracks, gouging, twisting, weld spatter, corrosion, stretching or lack of articulation between the links. Particular attention shall be given to links (see Figures 19 and 20) that have been reeved, due to the possibility of bending or twisting of the engaged link. Pitch (internal length) may be measured to verify stretch of chain.

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Bend

Twisted Link

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FIGURE 19 BENDS AND TWISTS

FIGURE 20 GOUGES, CHIPS AND CUTS

(e)

Any worn components should be measured to determine the degree of wear. Wear shall not exceed 10% of the nominal section in any plane. Wear by contact with other objects usually occurs on the outside of the straight portions of the links where it is easily seen and measured. Wear between adjoining links is hidden. The chain should be slack and adjoining links rotated to expose the inner end of each link (see Figure 21).

Wear

Entrance wear at bearing sur face

FIGURE 21 WEAR AT BEARING SURFACES

(f)

Upper and lower terminal fittings should be inspected for any signs of wear at their loadbearing points, nicks, cracks, gouging, stretching or distortion.

(g)

Connecting devices shall be inspected for any signs of wear at their load-bearing points, any excessive play of the load pin within the body halves, nicks, cracks, gouging, distortion or any impaired rotation of the body halves around the load pin.

(h)

For self-locking hooks, the following should be checked— (i)

the meeting of the catch to the body of the hook should be no more than indicated in Table 6; or

(ii)

the plane of the hook and safety latch should be within tolerances in Table 6.

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TABLE 6 MAX CLEARANCE BETWEEN HOOK AND LATCH FOR INSERVICE

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millimetres Size

Max. A

Max. B

2.4

3.5

7/8

3.2

4.5

5.2

NOTE: The tolerances are allowable after use and not to be considered as a manufacturer’s tolerance.

(i)

The tag shall be studied to identify the grade of the assembly and that the WLL does not exceed the rating of any component.

A sling inspection record shall be provided for each sling. NOTE: The application of a non-destructive testing methods may assist in the identification of faults otherwise not visible.

9.3 Defects requiring withdrawal from service If any of the following defects are visible, the sling shall be withdrawn from service and referred to a competent person: (a)

Where a tag becomes detached or illegible.

(b)

Defective safety catches and self-locking hooks.

(c)

Wear on mechanical connecting devices at their load-bearing points.

(d)

Excessive play of the load pin within the body halves of the connecting links.

(e)

Impaired rotation of the body halves of the connecting links around the pin.

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(f)

Cuts, nicks, gouges, cracks, weld spatter, excessive wear and corrosion, heat damage, bent or distorted links or any other defects. Shallow and rounded indentations in areas of low tensile stress may not be significant, but deep nicks in high-tension areas and sharp transverse nicks are unacceptable (see Figures 19 to 22).

(g)

Signs of overloading, such as any visible opening or twist of hooks or stretching of master links.

Testing and recording shall be carried out in accordance with AS 3775.1. Chain links or fittings having any defects shall be clearly marked to indicate rejection, and the sling shall be withdrawn from service until properly repaired.

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The sling may be returned to service after being assessed and identified by a competent person that it— (i)

is in good condition;

(ii)

has been retested; and

(iii)

has been retagged.

(a) Chain links with gouges, chips and cuts [refer to 9.2(d) and 9.3(f)]

FIGURE 22 (in part) DEFECTS

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10 REPAIR Any replacement component or part of the sling shall be in accordance with the appropriate Standard for that component or part. Where any chain link within the leg of a sling is required to be replaced due to damage, the whole of the chain within that leg shall be renewed. The repair of welded slings shall only be carried out by the manufacturer. Components that are cracked, visibly distorted or twisted, severely corroded or have deposits that cannot be removed shall be discarded or destroyed in such a manner to prevent re-use. Where appropriate (e.g. in the case of large hooks and large sling fittings), minor damage such as nicks and gouges may be removed by careful grinding and filing. Following repair, the surface should blend smoothly into the adjacent material without abrupt change of section. The complete removal of the damage should not reduce the thickness of the section at that point by more than 10% of the original manufacturer’s dimension in any plane. Repaired slings shall be proof tested, inspected and tagged, before being returned for use. Testing and recording shall be carried out in accordance with AS 3775.1. Sling hooks with safety catches and self-locking hooks with triggers that are non-load bearing may have safety catches, triggers, springs and retaining devices replaced, without retesting, provided no other damage is apparent.

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11 HAZARDS 11.1 Hazard identification Accidental release of a load, or release of a load due to failure of a component puts at risk, either directly or indirectly, the safety or health of those persons within the danger zone. In order to provide the necessary strength and durability of components AS 3775.1 gives requirements for their design, manufacture and testing to ensure the specified levels of performance are met. Since failure can be caused by the incorrect choice of grade and specification of component, AS 3775.1 also gives requirements for marking and test certificates. Any risk of injury during handling due to sharp edges, sharp angles or rough surfaces should be identified. 11.2 Risk assessment A risk assessment should be undertaken by a competent person before carrying out the operation required to be undertaken by the component or sling assembly. The assessment should take into account the following: (a)

The task to be carried out.

(b)

The range of methods by which the task can be done.

(c)

The type of component or sling assembly that will be required or that can be used.

(d)

The hazards involved and the associated risks.

(e)

The actual method and the other requisite plant and material.

NOTE: The risk assessment should address the proposed operation rather than each individual lift.

As a result of the risk assessment, the competent person should formulate a safe work method procedure, which should be monitored for ongoing effectiveness and modified whenever it is found to be deficient, when the task changes or when the associated risks change. NOTE: Guidelines on hazard identification and risk assessment procedures are given in AS/NZS ISO 31000.

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APPENDIX C

PERIODIC INSPECTION GUIDE FOR ALLOY CHAIN SLINGS—T(80) OR V(100) (Informative) Number of lift cycles per week

Inspection monthly

Inspection 3 monthly

Inspection 6 monthly

Inspection 12 monthly

1 to 5

—

6 to 25

—

26 to 200

—

Yes

—

201 plus

Yes

—

Yes Yes

—

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NOTE: The above is a guide and the inspection schedule has to be determined by the end user based on the duty cycle (of M3 as specified in AS 1418.1) and the environmental conditions of use.

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AS 3775.2:2014

10 REPAIR Any replacement component or part of the sling shall be in accordance with the appropriate Standard for that component or part. Where any chain link within the leg of a sling is required to be replaced due to damage, the whole of the chain within that leg shall be renewed. The repair of welded slings shall only be carried out by the manufacturer. Components that are cracked, visibly distorted or twisted, severely corroded or have deposits that cannot be removed shall be discarded or destroyed in such a manner to prevent re-use. Where appropriate (e.g. in the case of large hooks and large sling fittings), minor damage such as nicks and gouges may be removed by careful grinding and filing. Following repair, the surface should blend smoothly into the adjacent material without abrupt change of section. The complete removal of the damage should not reduce the thickness of the section at that point by more than 10% of the original manufacturer's dimension in any plane. Repaired slings shall be proof tested, inspected and tagged, before being returned for use. Testing and recording shall be carried out in accordance with AS 3775.l . Sling hooks with safety catches and self-locking hooks with triggers that are non-load bearing may have safety catches, triggers, springs and retaining devices replaced, without retesting, provided no other damage is apparent. 'c' $ C:

·c: 0.. C: <I> -0 <I> <I>

c � "'

::, O>

0 C:

a E

e.�

0 N {) <I> Cl 0

Any risk of injury during handling due to sharp edges, sharp angles or rough surfaces should be identified. 11.2 Risk assessment A risk assessment should be undertaken by a competent person before carrying out the operation required to be undertaken by the component or sling assembly. The assessment should take into account the following: ( a)

The task to be carried out.

(b)

The range of methods by which the task can be done.

(c)

The type of component or sling assembly that will be required or that can be used.

(d)

The hazards involved and the associated risks.

(e) The actual method and the other requisite plant and material. NOTE: The risk assessment should address the proposed operation rather than each individual lift. As a result of the risk assessment, the competent person should formulate a safe work method procedure, which should be monitored for ongoing effectiveness and modified whenever it is found to be deficient, when the task changes or when the associated risks change. NOTE: Guidelines on hazard identification and risk assessment procedures are given in AS/NZS 1SO 31000. www.standards.org.au

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AS 3776:2015

Lifting components for Grade T(80) and V(100) chain slings

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AS 3776—2015 2.3 MANUFACTURING METHODS AND WORKMANSHIP 2.3.1 Manufacture of forged components Each forged part of a component shall be forged hot in one piece. Excess metal from the forging operation shall be removed cleanly, leaving the surface free from sharp edges. After heattreatment, furnace scale shall be removed. Edges of machined surfaces shall be rounded to eliminate cutting edges and to ensure attainment of mechanical properties of the component. Welding shall not be used on forged components. 2.3.2 Surface finish The surface finish shall be one of the following: (a)

Self-colour. NOTE: See Clause 1.3.23 for the definition of self-colour.

(b)

Painted coating.

(c)

Any other surface finish that does not cause a degradation of the mechanical properties of the finished product.

2.4 MECHANICAL PROPERTIES Accessed by Wesfarmers Industrial and Safety Ltd on 21 Nov 2017 (Document currency not guaranteed when printed)

2.4.1 Permanent set When tested under the conditions specified in Appendix B, each lifting component shall be capable of supporting a force equal to the minimum proof test force specified by the relevant tables in Appendix A, without sustaining any permanent set of more than 1% of its original dimension after the load has been applied and removed. For testing of master links, refer to Clause 5.4.2 for the proof force calculations. 2.4.2 Strength Each lifting component in its finished condition shall be capable of achieving a minimum breaking force of 4 times the working load limit of the matching size Grade T(80) and V(100) chain under the conditions specified in Appendix B. NOTE: Compliance with the requirements of Clauses 2.4.2 and 2.4.3 can be demonstrated on a lifting component that has previously been loaded to demonstrate compliance with the requirements of Clause 2.4.1.

2.4.3 Ductility

2.4.3.1

General

The ductility of lifting components shall be such that, in the event of a lifting component being loaded under the conditions specified in Appendix B, Paragraph B1 until the lifting component meets or exceeds the minimum breaking load, it would not release the load. Any failure shall occur in a ductile manner. The failure should be away from any weld zone. Such a failure for a hook type of lifting component (excluding shortening and grab hooks) should be an opening out of the hook. Shortening hooks and grab hooks shall demonstrate deformation prior to release of the load. On completion of the static tensile test (see Clause 3.1.3), all links shall show evidence of elongation of not less than 20%.

2.4.3.2

Bend tests for welded links

The ductility of welded links shall be such that each link will pass the bend test for weld links given in Clause 5.5.2.

2.4.3.3

Bend and impact tests for self-locking hooks

The ductility of self-locking hooks shall be such that each self-locking hook will pass the bend and impact tests given in Clauses 7.6.1.2 and 7.6.1.4.

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AS 3776—2015

FIGURE 5.2 WELDED LINK

5.4 MECHANICAL PROPERTIES 5.4.1 Breaking force (BF) and elongation The breaking force (BF), in kilonewtons, shall be the force calculated by the following: BF = 4 × 9.81 × WLL where the working load limit is given in Tables A1 and A2, Appendix A.

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Links shall exhibit elongation in accordance with Clause 2.4.3.1. Links, including load-bearing pins, where used, shall have a breaking force at least equal to the breaking force (BF) as calculated above. 5.4.2 Proof force The proof force (in kilonewtons) shall be the force calculated by the following: (a)

Master-link (one leg): 2 × 9.81 × WLL(1 leg) where WLL is taken from Column 2 of Tables A1 and A2, Appendix A.

(b)

Master-link (multi-leg): 2 × 9.81 × WLL(multi-leg) where WLL is taken from Column 5 of Tables A1 and A2, Appendix A.

Permanent set shall meet the requirements of Clause 5.4.3. 5.4.3 Permanent set of master links Each master link shall be capable of supporting a force equal to the minimum proof test force specified by the relevant tables in Appendix A, applied under the conditions specified in Appendix B without sustaining any permanent set of more than 1% of its original dimension after the load has been applied and removed. If more than 1% occurs, refer to Table 5.4.3. TABLE 5.4.3 ALLOWABLE PERMANENT SET FOR MASTER LINKS Test number

Test result (% permanent set)

Test outcome

Set ≤1%

Pass

Set >1% ≤4%

Set >4%

Fail

Set ≤1%

Pass

Set >1%

Fail

Second test to be conducted

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AS 3776—2015

SE C TI O N

L I F TI N G

H O O K S

W IT H

L A TCH

6.1 GENERAL This Section sets out requirements for design, manufacture and testing of lifting hooks with a latch to ensure specified levels of performance are met. NOTE: See Figure 6.1 for illustrations of typical hooks with a latch.

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Hazards associated with these components are detailed in Section 11.

(a) Clevi s sli ng hook wi th latch

(b) ) Eye sling hook wi th latc h

FIGURE 6.1 TYPICAL LIFTING HOOKS WITH A LATCH

6.2 DESIGN 6.2.1 General The articulation and relative movement shall be in accordance with Clause 2.1. The form of the upper end shall be of the eye type or clevis type. Each hook shall have a spring-loaded latch conforming to Clause 6.2.2. 6.2.2 Hook latches The hook latch shall be able to close over a bar of diameter equal to the actual throat opening A as indicated in Figure 6.2. The latch shall engage in the point of the hook to form a complete closure of mating surfaces. With the hook in any orientation, the spring shall ensure that the latch is held positively in a closed position. Latches operated solely by gravity shall not be used. NOTE: The force required to fully open the latch should not exceed that which can be applied manually.

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AS 3776—2015

SE C TI O N

O TH E R

H O O K S

8.1 SCOPE OF SECTION This Section specifies requirements for design, manufacture and testing of other hooks to ensure specified levels of performance are met. Hazards associated with these components are detailed in Section 11. 8.2 SPECIFIC TYPES OF HOOKS 8.2.1 Shortening clutches and grab hooks Shortening clutches and grab hooks are usually used to reduce the length of a chain sling leg. Some shortening devices, such as grab hooks, de-rate the WLL of the sling by 25%. Other devices, such as shortening clutches or cradle grab hooks, may not de-rate the WLL of the sling. Advice regarding the appropriate de-ration should be available from the manufacturer.

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NOTE: See Figure 8.1 for illustrations of shortening clutches and grab hooks.

(a) Shor tening c lutch or hook

(b) ) Clevi s cradle grab hook

(d) Eye cradle grab hook

(e) Eye grab hook

FIGURE 8.1 SHORTENING CLUTCHES AND GRAB HOOKS

8.2.2 Hooks without a latch Hooks without a latch are usually used for specific applications, i.e. non-general use. Where there is a risk of the hooks becoming detached during use, a risk assessment shall be conducted. Section 11 provides guidance on conducting risk assessments.

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AS 3776—2015 A variety of hooks used for a range of applications may not have some form of latch. Hooks used on chain slings for logging and foundry applications are within this category. NOTE: See Figure 8.2 for illustrations of hooks without a latch.

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(a) Eye sling hook

( b) Clevi s sling hook

(d) Eye hook

(e) Clevis f oundr y hook

FIGURE 8.2 HOOKS WITHOUT A LATCH

8.3 DESIGN The articulation and relative movement shall be in accordance with Clause 2.1. 8.4 MATERIALS AND HEAT TREATMENT The materials and heat treatment of all load-bearing parts, including pins, shall be in accordance with Clause 2.2. 8.5 MANUFACTURING METHODS AND WORKMANSHIP Manufacturing methods and workmanship shall be in accordance with Clause 2.3. 8.6 MECHANICAL PROPERTIES The mechanical properties of all load-bearing parts, including pins, shall be in accordance with Clause 2.4. 8.7 TYPE TESTING OF MECHANICAL PROPERTIES Type tests and acceptance criteria shall be in accordance with Clause 3.1.

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AS 3776—2015

SE C TI O N

M A R K IN G

Each lifting component shall be legibly and indelibly marked in a place where the marking will not be removed by use and in a manner that will not impair the mechanical properties. The marking shall include at least the following information: (a)

The manufacturer’s identification.

(b)

Quality grade—T(8, 80 or 800) or V(10, 100 or 1000).

(c)

Nominal size on components or on links, product code of the manufacturer.

(d)

The traceability code.

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NOTES: 1 Care should be taken to ensure that the marking cannot be mistaken for the working load limit. 2 Item (a) should relate to the manufacturer’s literature for the WLL and applications for which the component is suitable.

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AS 3776—2015

APPENDIX A

COMPONENT WORKING LOAD LIMITS AND TEST FORCES (Normative) TABLE A1 WORKING LOAD LIMITS AND TEST FORCES [Grade T(80)] 1

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Master and intermediate links (2, 3 and 4 legs), WLL

Single leg master link and components Chain size mm

WLL Proof force (see Note 3)

WLL

Proof force

Breaking force

6 7 8

1.1 1.5 2.0

21.6 29.4 39.2

43.2 58.9 78.5

1.9 2.6 3.5

37.3 51.0 68.7

74.6 102 137

10 13 16

3.2 5.3 8.0

62.8 104 157

126 208 314

5.5 9.2 13.8

108 181 271

216 361 542

19 20 22

11.2 12.5 15.0

220 245 294

439 491 589

19.4 21.6 26.0

381 424 510

761 848 1020

26 32

21.2 31.5

416 618

832 1236

36.7 54.5

720 1069

1440 2139

NOTES: 1

The proof force is 2 times WLL (see Clause 5.4.2).

The breaking force shall be a minimum of 4 times WLL.

WLL for multi-leg slings is rated for sling angles at 60°, i.e. 1 leg WLL × 1.73.

The WLL shall be determined in accordance with Appendix C.

Some manufacturers may have developed components for higher WLLs.

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AS 3776—2015 TABLE A2 WORKING LOAD LIMITS AND TEST FORCES [Grade V(100)] 1

Single leg master link and components

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Chain size mm

Master and intermediate links 2, 3 and 4 legs WLL Proof force (see Note 2)

WLL t

Proof force

Breaking force

4 5 6

0.63 1.0 1.4

12.4 19.6 27.5

24.7 39.2 54.9

1.1 1.7 2.4

21.6 33.4 47.1

43.2 66.7 94.2

7 8 10

1.9 2.5 4.0

37.3 49.1 78.5

74.6 98.1 157

3.3 4.3 6.9

64.7 84.4 135

129 169 271

13 16 18

6.7 10 12.5

131 196 245

263 392 491

11.6 17.3 21.6

228 339 424

455 679 848

19 20 22

14 16 19

275 314 373

549 628 746

24.2 27.7 32.9

475 543 645

950 1087 1291

23 26 28 32

21 26.5 31.5 40

412 520 618 785

824 1040 1236 1570

36.3 45.8 54.5 69.2

712 899 1069 1358

1424 1797 2139 2715

NOTES: 1

The proof force is 2 times WLL (see Clause 5.4.2).

The breaking force shall be a minimum of 4 times WLL.

WLL for multi-leg slings is rated for sling angles at 60°, i.e. 1 leg WLL × 1.73.

The WLL shall be determined in accordance with Appendix C.

Some manufacturers may have developed components for higher WLLs.

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AS 3776—2015

BC A E

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FIGURE B1 TYPICAL MARKS FOR DETERMINATION OF PERMANENT SET— HOOK WITHOUT LATCH

FIGURE B2 TYPICAL MARKS FOR DETERMINATION OF PERMANENT SET— SELF-LOCKING HOOK

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AS 3776—2015

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FIGURE B3 TYPICAL MARKS FOR DETERMINATION OF PERMANENT SET— HOOK WITH LATCH

C A

FIGURE B4 TYPICAL MARKS FOR DETERMINATION OF PERMANENT SET— OBLONG LINK

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AS 3777—2008

Australian Standard® Shank hooks and large eye hooks— Maximum 60 t

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AS 3777—2008 Bearing locations shall be machined to a size that will suit the bearing to be fitted. The junction of the shank and the collar shall be of a shape that will minimize stress concentrations. 6.6 Latches Latches shall be spring-loaded or self-closing. The latch shall ensure that the load or attached device cannot become accidentally unhooked and shall engage in the point of the hook to form a complete closure of mating surfaces. With the hook in any orientation, the spring or other device shall ensure that the latch is held positively in a closed position. Latches operated solely by gravity shall not be used for hooks used in sling assemblies. [See Appendix E, Item (h)]. NOTE: The force required to fully open the latch should not exceed that which can be applied manually.

7 MARKING Where a hook is an integral part of a block or other lifting appliance, specific marking on the hook is not required; however, any marking shall be such that it will not be likely to cause an incorrect interpretation of the WLL of the block or lifting appliance.

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Any marking shall be either raised or indented. Where the marking is indented, the marks shall not have sharp edges, and the depth and location of the marks shall not impair the mechanical properties or damage any surface finish of the hook. Where a hook is not an integral part of a lifting appliance, the hook shall be permanently and legibly marked with the following information: (a)

Manufacturer’s identification.

(b)

Working load limit.

(c)

Identification marking to correlate the hook to the test certificate.

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AS 3777—2008 8 MECHANICAL PROPERTIES 8.1 Permanent set Each hook shall be capable of supporting a force equal to the minimum proof test force specified by Clause 10.1, applied under the conditions specified in Appendix C, without sustaining any permanent set of more than 1% of its original dimension after the load has been applied and removed and determined in accordance with Item (e) of Appendix C. 8.2 Strength Each hook shall be capable of supporting a test load of F times the working load limit of the hook under the conditions specified in Appendix C, where F is— (a)

for Grade M hooks .............................................................................................5; or

(b)

for Grades P and S hooks ................................................................................................ 4.

NOTE: Compliance with the requirements of Clauses 8.2 and 8.3 can be demonstrated on a hook that has previously been loaded to demonstrate compliance with the requirements of Clause 8.1.

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8.3 Ductility The ductility of hooks shall be such that, in the event of a hook being loaded under the conditions specified in Appendix C until the hook meets or exceeds the minimum breaking load without releasing the load, any failure shall occur in a ductile manner. Such a failure shall be an opening out of the hook. 9 TYPE TESTING OF MECHANICAL PROPERTIES 9.1 General NOTES: 1

The test of each design is known as the type test, which determines the adequacy of the design for achieving the required performance.

Each change in manufacturing process, grade of material, design, and size necessitates separate type testing, to demonstrate compliance with the requirements of Clause 8.

In addition to type testing, effective quality control necessitates systematic testing of each lot or batch, to ensure continuing compliance with the requirements of Clause 8.

Means for demonstrating compliance with this Standard are given in Appendix D.

9.2 Tests

9.2.1 Mechanical properties Compliance of each design with the requirements of Clause 8 shall be demonstrated.

9.2.2 Test for deformation A sample shall be tested. The sample shall sustain the manufacturing proof force specified for the hook. Following the removal of the force, the dimensions shall comply with the manufacturer’s specifications. Permanent set shall comply with Clause 8.1.

9.2.3 Static tensile test A sample shall be tested. The sample shall have a breaking force at least equal to the minimum value specified for the hook and meet the requirements of Clause 8.2. NOTE: This test may be carried out on the same hooks subjected to the deformation test.

9.2.4 Examination for articulation and relative movement A sample of each articulating design shall be visually examined to ensure it freely articulates so that the force is transmitted axially.

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AS 3777—2008 9.3 Acceptance criteria for type tests Where the sample passes all tests listed in Clause 9.2, the hook of the size and type submitted for type testing shall be deemed to conform to this Standard. Where the sample fails any of the tests listed in Clause 9.2, two further samples shall be tested. Both samples shall pass all tests in order for the hook of the size and type submitted for testing to be deemed to conform to this Standard. 10 PROOF TESTING 10.1 Proof loading Each eye hook in its finished condition shall be subjected to a proof force in accordance with Table 1 applied under the conditions specified in Appendix C. Proof testing may be performed as part of the finished assembled product or lifting sling. Each shank hook in its finished condition shall be subjected to a proof force in accordance with Table 1 applied under the conditions specified in Appendix C after machining of the shank. TABLE 1

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MINIMUM PROOF FORCES WLL, t

Minimum proof force, kN

<20

(2 × WLL) × 9.81

≥20 <40

(WLL + 20) × 9.81

≥40

(1.5 × WLL) × 9.81

NOTE: The WLL shall be in accordance with Appendix B.

10.2 Requirements The hook shall— (a)

withstand the application of the proof force, without sustaining damage that may affect its intended function; and

(b)

after testing, meet the permanent set requirements of Clause 8.1.

A competent person (see Clause 3.1) shall be satisfied that these requirements have been complied with. 10.3 Test certificate The proof testing shall be recorded on a test certificate, which shall bear the following information: (a)

Description.

(b)

Surface finish.

(c)

Working load limit.

(d)

Proof force.

(e)

Date of proof test.

(f)

Number tested.

(g)

Identification marking correlating with the hooks.

(h)

A declaration that the hooks comply with this Standard.

(i)

The name and address of the manufacturer or supplier.

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AS 3777—2008 (j)

The name and address of the testing establishment.

(k)

The name of the signatory.

(l)

Type of certificate (e.g., certifying authority, supplier). NOTE: The manufacturer or supplier should retain the original test certificate for not less than 10 years.

11 CARE AND USE

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Care and use of hooks shall be in accordance with Appendix E.

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AS 3785—2006

AS 3785.7—2006

Australian Standard® Underground mining—Shaft equipment Part 7: Sheaves

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AS 3785—2006 (b)

Spoke connections For bolted spoke connections, fitted bolts or equivalent should be used.

(c)

Bearings Ball and roller bearings for rotating shafts should be of the self-aligning type with one bearing fixed against lateral movement and the other free to move laterally.

(d)

Inertia The inertia of the fully assembled sheave should be minimized.

7 NON-DESTRUCTIVE TESTING All components of the sheave assembly, excluding bearings, shall be non-destructively tested as follows: (a)

Rims, spokes or web, hub, shaft These components shall be subject to magnetic particle examination and either radiographic or ultrasonic examination after final machining to ensure that the components are free of defects that could significantly affect their mechanical properties and structural integrity. These examinations shall be carried out in accordance with AS 1065, AS 1171, AS/NZS 2574, AS 3507.1 and AS 3507.2, as appropriate. X-radiography is required at the joints of spokes or webs if the material is cast.

(b)

Welding Welds shall be non-destructively tested in accordance with the requirements of AS/NZS 1554.1, AS/NZS 1554.4, AS/NZS 1554.5 or AS 1988, as applicable.

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8 TEST CERTIFICATES 8.1 Certificates required The following certificates shall be provided with each sheave: (a)

(b)

Component test certificates, which shall state the following: (i)

Description of component.

(ii)

Part number.

(iii)

Date of manufacture.

(iv)

Material specification, including heat treatment.

(v)

Report on non-destructive tests.

Certified sheave assembly drawing, which shall contain the following: (i)

Name and address of manufacturer.

(ii)

Part number for each component and the serial number of the assembly.

(iii)

Mass of the sheave assembly, in kilograms.

(iv)

Inertia of sheave assembly, in kilograms metre squared.

(v)

Diameter of rope for which sheave is designed, in millimetres.

(vi)

The rope break load for which the sheave is designed, in kilonewtons.

(vii) The wrap angle for which the sheave is designed, in degrees. (viii) The fleet angle for which the sheave is designed, in degrees. (ix)

The maximum allowable wear profile of the rope groove.

(x)

Insert material specification and dimensional data, if applicable.

(xi)

The design working life, in revolutions.

(xii) The design minimum ambient temperature.

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AS 3785—2006 Each certificate shall bear the name and address of the manufacturer, the date of test, qualification and status of the signatory of the testing organization, where appropriate. A copy of each certificate shall be retained by the manufacturer and the supplier. The certificate shall include a declaration stating that the component has been inspected by a responsible and competent person and is in compliance with the requirements of this Standard. 9 MARKING Each component shall be permanently and legibly marked with its part number. The date of manufacture, rope diameter, design wrap angle, design fleet angle, design rope break load and the sheave manufacturer’s business name or abbreviated name shall be marked on at least one component of the sheave. The symbols shall be as large as practicable but not less than 5 mm high. Where marking is carried out by stamping, it shall be effected in a low stress area, and care shall be taken to ensure that the marks are neither too ‘sharp’ nor too deep.

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AS 3785—2006

APPENDIX A

INFORMATION TO BE PROVIDED BY THE PURCHASER (Informative) The following information should be provided by the purchaser: Winding system geometry, including conveyance rope configuration.

(b)

Winding system performance data.

(c)

Conveyance dead load, personnel or material or mineral live loads.

(d)

Winding rope type and specification.

(e)

Sheave wrap angle.

(f)

Sheave maximum fleet angle.

(g)

Rope speed.

(h)

Preferred configuration of sheave assembly (i.e., shaft type, bearing type, rim insert, etc.).

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(a)

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AS 3785—2006

APPENDIX B

INFORMATION TO BE PROVIDED BY THE SUPPLIER (Informative) The following information should be provided by the supplier: Details of installation requirements for location and alignment tolerances.

(b)

The recommended inspection and maintenance procedures.

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(a)

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AS 3785—2006

APPENDIX C

SHEAVE RIM DIMENSIONAL PROPORTIONS (Informative) C1 SCOPE This Appendix sets out guidelines for determining the dimensional proportions of the sheave rims, with and without inserts. C2 SHEAVE RIMS WITHOUT INSERTS Sheave rims may be designed to be used with or without inserts. For rims without inserts, the dimensions in Figure C1 should be used for the initial design selection. C3 SHEAVE RIMS WITH INSERTS Where inserts are used, the minimum dimensions in Figure C2 should be used for the initial design selection.

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C4 SHEAVE GROOVE DIMENSIONS For rims with or without inserts the groove diameter (2r) should be 7.5% to 12% greater than the nominal rope diameter (d) for which the sheave is designed and the angle (α) should be between 30° and 60°, the value being dependent on the maximum fleet angle of the rope on the sheave. Typically sheave groove depths are in the range 2 to 3 times the nominal rope diameter.

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AS 3785—2006

e d

r c

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FIGURE C1 EXAMPLE OF A SHEAVE PROFILE WITHOUT INSERT

TABLE C1 EXAMPLES OF DIMENSIONS FOR SHEAVES WITHOUT INSERTS millimetres D

> 1 000 > 1 500

≤ 1 000 ≤ 1 500 ≤ 2 000

30 35 35

75 75 75

20 25 30

15 18 22

> 2 000 > 2 500 > 3 000

≤ 2 500 ≤ 3 000 ≤ 3 500

50 50 70

100 150 150

35 40 45

26 30 33

> 3 500 > 4 000 > 4 500

≤ 4 000 ≤ 4 500 ≤ 5 000

100 100 100

200 200 200

50 50 50

38 38 38

> 5 000 > 6 000

≤ 6 000 ≤ 7 000

100 110

200 200

60 60

45 45

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AS 3785—2006

c Typical insert

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FIGURE C2 EXAMPLE OF A SHEAVE PROFILE WITH INSERT

TABLE C2 EXAMPLES OF DIMENSIONS FOR SHEAVES WITH INSERTS millimetres D

> 1000 > 1500

≤ 1000 ≤ 1500 ≤ 2000

20 25 30

75 75 80

20 25 30

15 18 22

> 2000 > 2500 > 3000

≤ 2500 ≤ 3000 ≤ 3500

40 50 60

100 170 170

35 40 45

26 30 33

> 3500 > 4000 > 4500

≤ 4000 ≤ 4500 ≤ 5000

65 70 75

220 220 220

50 50 50

38 38 38

> 5000 > 5500 > 6000

≤ 6000 ≤ 6000 ≤ 7000

80 90 110

220 220 220

60 60 60

45 45 45

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AS 3785—2006 TABLE D1 MAXIMUM ALLOWABLE TREAD PRESSURE BETWEEN ROPE AND SHEAVE Sheave material

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Rope construction

Cast iron MPa

Cast steel MPa

6 × 19 + IWR or IWS ordinary lay

2.7

5.5

6 × 19 + IWR or IWS Lang’s lay

3.1

6 × 25 + filler + FC ordinary lay

3.4

6.5

6 × 25 + filler + FC Lang’s lay

3.9

7.5

6 V × 15/12/FC Lang’s lay

5.5

6 V × 12/12/FC Lang’s lay

5.1

6 V × 10/12/3 FC Lang’s lay

4.6

9.2

6 V × 9/12/3 FC Lang’s lay

3.8

7.5

6 V × 7/3 FC Lang’s lay

3.1

6.2

8 Outer strands, compacted, ordinary lay

5.5

8 Outer strands, compacted, Lang’s lay

9 × 6/6 × 7/3 FC or IWRC Lang’s lay

6.2

12.2

9 × 8/6 × 8/9 FC or IWRC Lang’s lay

6.4

12.6

9 × 8/2 / 6 V FC or IWRC Lang’s lay

6.2

12.2

12 Outer strands, compacted, ordinary lay

6.5

13.8

12 Outer strands, compacted, Lang’s lay

18 × 7 Ordinary lay

6.5

13.8

Non-rotating rope with 12–18 outer strands, non compacted, ordinary lay

6.5

13.8

Non-rotating rope with 12–18 outer strands, non compacted, Lang’s lay

7.1

Non-rotating rope with 12–18 outer strands, compacted, ordinary lay

7.1

Non-rotating rope with 12–18 outer strands, compacted, Lang’s lay

7.8

14.5

Full locked coil rope

8.5

NOTES: 1

This Table is for cast iron with an average Brinell hardness of 125 and cast steel (average 0.3/0.4% carbon) with a Brinell hardness of 260.

This Table applies to sheaves without inserts.

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AS 3785—2006

APPENDIX E

SHEAVE DIAMETER (Informative) The rope pitch circle diameter (D) of a sheave is normally related to the rope diameter (d). Statutory authorities may specify a different D/d ratio based on the rope construction or winding velocity, or both. As a guide the following values may be used for permanent installations to provide for adequate life of ropes and sheaves: (a)

Normal stranded ropes: .............................................................................. D/d ≥ 80.

(b)

Locked-coil ropes: ....................................................................................D/d ≥ 100.

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The D/d value given for stranded ropes is for grade 1760 MPa wire and should be increased for high hoisting speeds (i.e., greater than 10 m/s) and higher wire grades. The D/d value should be increased by 5% for each 1 m/s above 10 m per second and, for grade 2160 MPa wire, should be increased by a further 8%. Lower values of D/d may be used for temporary installations such as shaft sinking where the rope and sheave life may not need to be maximized.

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AS 3785—2006

APPENDIX F

ALLOWABLE WEAR FOR SHEAVE RIMS WITHOUT INSERTS (Informative) The rim of each sheave should be designed such that wear in the ‘vee’ from wire rope contact is allowed for in the design of the sheave. The designer should determine what the maximum wear limits are to be for each sheave rim for both the major and minor axes of the sheave. These wear limits should be clearly shown on the certified sheave assembly drawing. Each sheave rim should be examined regularly on site by the user for wear during the whole of its working life. Examinations should be carried out at half-yearly intervals. When an examination shows that one or both wear limits (as shown on the certified sheave assembly drawing) is exceeded, the worn sheave should be removed from service immediately. Should an on-site examination of a worn spoked sheave show that the ends of the spokes are visible in the rim vee, the sheave should be removed from service immediately.

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If the vee groove, in the immediate proximity of the root, has worn in such a manner that the wire rope is impeded from bedding into the bottom of the groove smoothly, the user should machine the vee groove, to the radius (r) indicated in Paragraph C4, Appendix C, to remove that defect.

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AS 3850.1:2015

Prefabricated concrete elements Part 1: General requirements

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AS 3850.1—2015 NOTE: Expansion anchors should be installed, inspected and verified in accordance with the supplier’s recommendations and special attention should be paid to the correct drilling of holes and tightening to the correct installation torque and checking of the required residual torque. Expansion anchors should also be torque-controlled, and of a type recommended by the supplier for repetitive loads of combined tension and shear.

Deformation-controlled anchors, including self-drilling anchors and drop-in (setting) impact anchors, shall not be used. Post-installed brace inserts shall be stamped with the manufacturer’s name or symbol, which shall be visible after installation. C2.5.3 Deformation-controlled anchors should not be used because they— (a)

have no additional expansion (and hence additional load capacity) after the initial setting process;

(b)

fail without warning; and

(c)

are highly sensitive to installation procedures.

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Torque-controlled anchors may be used because after their installation the application of load causes these anchors to behave elastically until a load is reached at which they first begin to slip. After first slip, the anchor exhibits ‘ductile’ load behaviour. Cyclic load conditions (e.g. wind loads) can result in failure of an expansion anchor that has been loaded in excess of its first slip load, even if subsequent load cycles do not exceed the first slip load. 2.5.4 Cast-in fixing and brace inserts (ferrules) The WLL for cast-in fixing and brace inserts shall be determined in accordance with Clause 2.2 and shall comply with the following: (a)

Where standard ISO metric threaded fixing inserts and bolts are used, they shall comply with AS 1110 series.

(b)

Where other types of fixings inserts are used, such as cast-in helical wire-coil inserts, the fixing bolts used shall be compatible with the fixing inserts.

(c)

The engagement length of the bolt in the insert shall be as specified by the supplier of the system.

(d)

Inserts, when used in tension, shall be designed with a steel capacity that exceeds that of the class of the matching bolt and at a minimum, that of a Class 4.6 bolt in accordance with AS 1111.1.

(e)

Fixing inserts for the prefabricated concrete element connection to roof framing and other structural members shall be designed to resist the forces imposed on the connections, as determined by the appropriate Australian Standard and National Construction Code (NCC), Volume 1, Building Code of Australia.

(f)

Torque limits for cast-in components shall be provided in the erection documentation.

C2.5.4 It is important to ensure that the insert and bolt have matching threads and have been checked by the user to be compatible. 2.6 LIFTING CLUTCHES The WLL for lifting clutches shall be determined in accordance with Clause 2.2. Lifting clutches shall be manufactured from ductile materials. During the design validation, when loaded in tension to ultimate failure, lifting clutches shall comply with the following: (a)

Failure shall occur in a ductile manner away from any weld zone.

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AS 3850.1—2015 (b)

There shall be evidence of distortion and plastic deformation of the clutch assembly.

(c)

All fracture faces shall demonstrate ductile failure mechanisms.

When tested in any orientation (as approved by the supplier) with a compatible anchor, failure of the anchorage shall occur without fracture of any component of the lifting clutch. All cast clutch components shall be 100% fluorescent magnetic particle tested in accordance with AS 1171, and shall contain no linear indications. Each lifting clutch shall be proof-tested, certified and uniquely identified prior to being placed into service. The proof test shall subject the device to a load of 2.0 times its WLL. Prior to each use, inspections of the lifting clutches shall be conducted to check for wear and deformation to supplier’s specification. A proof test using a load equal to 1.2 times the WLL shall be conducted and recorded for each lifting clutch at intervals of not more than 12 months commencing from the date of first use.

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Each clutch shall be permanently marked with the following information: (i)

A unique identifier (traceable to the proof tests).

(ii)

The manufacturer’s symbol or name.

(iii)

Its WLL or compatible anchor identifier.

C2.6 Suitable identification of lifting clutches may be by permanent marking on the clutch itself or attachment of a durable tag. Following visual inspection of the lifting clutch, if there are any safety concerns, a proof test and a fluorescent magnetic particle should be conducted. 2.7 BRACES 2.7.1 General The WLL for braces shall be determined in accordance with Clause 2.2. Brace adjustment mechanisms shall have stops on the threads to prevent over-extension, and on retaining devices to prevent unintentional dislodgment of the shear pins, including the telescopic adjustment pin and the brace foot pin. Shear pins shall be constructed so they cannot be undone without the use of a tool. The bracing foot or shoe shall be designed so as to prevent lateral displacement of the shoe from the fixing insert after installation. The following information, for all braces, shall be readily available at the erection site: (a)

WLL (in kilonewtons) for a fixed length brace and at minimum, maximum and intermediate extensions for telescopic braces.

(b)

WLL (in kilonewtons) when used with specified configurations of secondary bracing, including knee bracing and stability bracing.

C2.7.1 The stability of a prefabricated concrete element in the temporary braced condition may be jeopardized if shear pins on the braces are removed either accidentally or as acts of vandalism. To minimize the risk of this occurring, site security should be appropriate to reduce the risk of vandalism. Erection procedures should be such as to ensure that a brace is not removed until the prefabricated concrete element is secured to the structure. Shear pins on braces should be purpose-made, simple to install and unable to be removed without appropriate equipment or deliberate force.

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A8 TESTING OF LIFTING CLUTCHES A8.1 General In addition to the general requirements set out in Clause 2.6, lifting clutches shall also be tested in accordance with Paragraph A8.2. A8.2 Tension (axial) test of the lifting clutches A8.2.1 General Testing of lifting clutches shall be conducted to confirm the following requirements: (a)

Design validation to determine Ru—testing to ultimate load.

(b)

Proof testing in accordance with Clause 2.6.

A8.2.2 Apparatus for tension testing of the lifting clutch The following apparatus shall be required: (a)

A compatible lifting insert for use with the insert.

(b)

A tensile testing machine compliant with Class A of AS 2193, capable of applying a load to the lifting clutch using a uniform minimum crosshead travel speed of 20 mm/min.

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A8.2.3 Procedure The procedure shall be as follows: (a)

Connect the lifting clutch to the insert.

(b)

Using a constant crosshead travel speed of 20 mm to 50 mm/min, apply the load to the lifting clutch until—

(c)

(i)

failure occurs when conducting a design validation test; or

(ii)

proof-load when conducting proof testing.

Examine the specimen for— (i)

finite evidence of ductile fracture and plastic deformation adjacent to the failure when conducting a design validation test; and

(ii)

no signs or failure or excessive distortion when conducting proof testing.

A9 ADDITIONAL TESTING FOR POST-INSTALLED BRACE INSERTS A9.1 General This Paragraph sets out the test and evaluation procedure for determining the design capacities of torque-controlled expansion anchors (post-installed brace inserts) used in bracing shoes (foot plates). The test and evaluation procedures are limited to torque-controlled expansion anchors. NOTE: These procedures are broadly based on the guideline for European technical approval ETAG 001.

The additional testing specified in this Paragraph is limited to determining the design capacities of post-installed brace inserts, free from the effects of edge distance, concrete reinforcement and spacing, and excluding the splitting mode of concrete failure. The tests in this Paragraph do not cover impact loading and seismic loading. Testing shall be conducted in a controlled laboratory environment using representative postinstalled brace insert samples, installed in accordance with the supplier’s specifications and applied to concrete specimens with minimum performance requirements, as specified by this Paragraph.

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Bullivants | Page 446 of 692

AS/NZS 4344:2001

1.4.2 Joining devices The relevant sections of joining devices shall freely pass through the internal dimensions of the chain link, freely pass through the eyes of hooks or other componentry and provide free articulation. 1.4.3 Clevises on chain components The dimensions of clevises on chain components shall freely assemble through the internal dimension of the chain link and provide free articulation. 1.4.4 Other components The dimensions of components other than those mentioned in Clauses 1.4.1 to 1.4.3, including hooks, shall allow for sufficient articulation so that the load will be transmitted axially. 1.5 BREAKING FORCE When the breaking force of the chain and component is determined in accordance with the method described in Appendix A, it shall be not less than the minimum breaking force given in Table 3. I. 1.6 MARKING 1.6.1 Identification of chain The chain shall be permanently and legibly marked with the manufacturer's identification and the digits 4344 (i.e. the number of this Australian/New Zealand Standard), followed by a hyphen and the first two digits of the chain's lashing capacity (e.g. 4344-2.5 represents 2500 kg due to manufacturing limitations). The marking shall be repeated at intervals not exceeding 500 mm and the characters on the links shall be not less than 1.5 mm high for chains less than 8 mm, and not less than 2 mm high for chains 8 mm and above. 1.6.2 Identification of components The components used in a load restraining system shall be permanently and legibly marked with information, avoiding any possibility that the marking could be mistaken for the lashing capacity: (a )

Chain size.

(b)

Manufacturer or supplier's trademark or identification.

(c)

Identification of grade or reference to AS/NZS 4344.

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Bullivants | Page 449 of 692

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AS/NZS 4345:2001

1.4 DIMENSIONS 1.4.1 Diameter (three-strand hawser-laid rope only) When determined in accordance with the method described in AS 4143.1, the diameter of three-strand hawser-laid rope shall not differ from the value specified in Tables 2 to 8 in AS 4142.2-1993, as appropriate, by more than 10% for diameters less than 40 mm or by more than 5% for diameters of 40 mm and greater. 1.4.2 Length of rope The length of the rope shall be calculated by dividing the mass of the coil, without lashings or wrappings, by the linear density determined by the method described in AS 4143.1. unless otherwise specified, three-strand hawser-laid rope shall be supplied in lengths of 250 m. Unless otherwise specified, eight-strand plaited rope shall be supplied in lengths as specified in Tables 9 to 12 in AS 4142.2-1993. 1.4.3 Linear density When determined in accordance with the method described in AS 4143.1, the linear density of the rope shall not vary from the values given in Tables 2 to 12 in AS 4142.2-1993, as appropriate by more than(a)

10% for a rope of diameter or size number less than or equal to 8;

(b)

8% for a rope of diameter or size number greater than 8 but less than 16; or

(c)

5% for a rope of diameter or size number equal to or greater than 16.

1.4.4 Length of ten lays The length of 10 lays when measured in accordance with AS 4143.1 shall not exceed the value given in Tables 2 to 12 in AS 4142.2-1993. 1.5 BREAKING FORCE When the breaking force of the rope is determined in accordance with the method described in AS 4143.1, it shall be not less than the minimum breaking force given in Tables 2 to 12 in AS 4142.2-1993, as appropriate. 1.6 MARKING 1.6.1 Identification of fibre

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The fibre in all rope of diameter greater than or equal to 12 mm or size number greater than or equal to 12, shall be identified by a single coloured yarn of polyethylene or multifilament viscose rayon of 56 tex inserted in the centre of one of the strands. The colour of the identifying yarns shall be as set out in Table 1. The thread used for identification purposes shall be regarded as an additional yarn in the strand. NOTE: 1 kilotex (ktex) = 1 g/m.

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TABLE 1 FIBRE IDENTIFICATION COLOUR CODING CHART Type of rope fibre

Colour of identifying yarn

Polyester (PES)

Blue

Polyethylene (PE) staple

Orange

Polypropylene (PP)

Brown

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AS/NZS 4345:2001

1.6.2 Identification of lashing capacity All transport fibre rope shall be identified by a black-coloured marker yarn on the outside of one of the strands. The lashing capacity (LC) of the rope shall be identified by the addition of a coloured yarn on the outside of the same strand in accordance with Table 2.

TABLE 2 LASHING CAPACITY COLOUR CODING CHART Identifying colour

Lashing capacity (LC) Kg

100

Black

300

Yellow

500

Green

Light blue

700

1.6.3 Identification of coil or flange reel Each coil or flange reel of rope manufactured in accordance with this Standard shall be permanently and legibly marked with the following information: (a)

Lashing capacity (LC), in kilograms.

( b)

Nominal length, in metres.

(c)

Nominal size or size or size number.

(d)

Manufacturer's name or trademark, or both.

( e)

Generic type of fibre and form of filaments from which the rope is made.

(f)

Manufacturer's traceability code.

(g)

Date, date code or batch number.

1.7 PACKAGING

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All transport fibre rope shall be neatly coiled and suitably protected to prevent damage during transit. Rope ends shall be secured to prevent unlaying or unravelling of the strands, as specified in Clause 2.2.1.4. The packaging shall include the following: (a)

Manufacturer's name and address or trademark, or all three.

( b)

Generic type of fibre and form of filaments or film from which the rope is made.

(c)

Month and year of manufacture.

(d)

Length of coil, in metres.

( e)

Diameter of the rope, in millimetres.

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Bullivants | Page 454 of 692

AS/NZS 4380:2001

1.4 MARKING 1.4.1 Complete assembly The fixed end and adjustable end (refer to Figure 1) of the webbing components of lashing assembly shall be permanently and legibly marked with the following information: (a)

Lashing capacity (LC) in kilograms (kg).

(b)

Length, in metres.

(c)

Caution statement, as follows: CAUTION: MUST NOT BE USED FOR LIFTING

(d)

Material from which the webbing is manufactured.

(e)

Name of manufacturer or supplier.

(f)

Manufacturer's traceability code.

(g)

A compliance statement referring to this Standard, i.e. AS/NZS 4380.

A space shall be reserved on each lashing, or complete system, for the certification mark and year of manufacture (if required). 1.4.2 Label Labels or printing shall be one of the following colours, which will indicate the type of webbing material (refer to Figure 3 for a typical label format): (a)

Blue .................................................................................. polyester (PES) webbing.

(b)

Green ................................................................................ polyamide (PA) webbing.

(c)

Brown .......................................................................... polypropylene (PP) webbing.

Lashing capacity (LC) in kilograms ............................... Webbing material ......................................................... Length ......................................................................... Manufacturer's or supplier's symbol or trade marking ..... Manufacturer's traceability code .................................... This Standard (AS/NZS 4380) .......................................

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(a) Front Label

Lashing capacity (LC) in kilograms (kg) ......................... Webbing material ......................................................... Manufacturer's or supplier's symbol or trade marking ..... Manufacturer's traceability code .................................... This Standard (AS/NZS 4380) .......................................

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NOTE: Concealed under the cover overlap for future validation.

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FIGURE 3

TYPICAL LABEL FORMAT COPYRIGHT Bullivants | Page 455 of 692

AS/NZS 4380:2001

1.4.3 Tensioning device Mountable tensioning devices shall be marked with at least the manufacturer's or supplier's name or trademark and the lashing capacity (LC). 1.5 PACKAGING Webbing restraint systems shall be suitably protected to prevent damage during transit. The packaging shall include the following: (a )

Manufacturer's name and address or trademark, or all three.

(b)

Generic type of fibre and filaments from which the webbing is made.

(c )

A user instruction label or leaflet which shall be provided with each webbing restraint system and which shall contain advice on safe use and precautions necessary during use, covering at least(i )

information and warnings on risks; and

(ii)

particular information on the type of webbing restraint system and its intended use.

NOTES: Appropriate information to be included in the instruction label or leaflet should be selected from Appendix D. 2

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AS 4497:2018

Roundslings—Synthetic fibre

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AS 4497—2018

Effective length (d) Roundsling with protective sleeve

Effective length

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(e) Roundsling with protective sleeve and both sides reinforced

Effective length (f) ) Roundsling with protective sleeve and one sides reinforced

FIGURE 1.1 (in part) TYPICAL ROUNDSLINGS

The woven cover acts as the protective element for the load bearing yarn. It overlaps to allow for the longitudinal conjunction seam.

Endless polyester yarn as load bearing element.

FIGURE 1.2 EXAMPLE OF ROUNDSLING SEGMENT SHOWING CUTAWAY OF INTERNAL LOAD-BEARING ELEMENT

1.4 COMPETENT PERSON REQUIREMENTS 1.4.1 General Persons manufacturing, testing and using roundslings shall be competent persons for the tasks they are performing, including being competent to detect and evaluate defects and weaknesses that may affect the intended performance of the roundslings.

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AS 4497—2018 2.2.10

Marking

2.2.10.1

Sling information

Each sling shall be permanently and legibly marked with the following information in English: (a)

Working load limit for direct load and various lifting configurations in tonnes or kilograms.

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The WLL of multi-leg slings shall be stated on the tag attached to the master link. The WLL on the master link tag of the sling assembly shall override the WLLs of the individual components. (b)

Fibre material (e.g. nylon, polyester, polypropylene or aramid polyamide, as applicable).

(c)

Month and year of manufacture of the sling.

(d)

Identification marking to correlate the sling to a test certificate or batch number, and a unique individual identification for inspection traceability.

(e)

The nominal length in metres.

(f)

Manufacturer’s identification, manufacturer’s name, symbol, trade mark or other unambiguous identification and, where applicable, the name and address of the authorized representative.

(g)

A section of the tag shall be stitched under the cover, which shall also be marked with information from Clause 2.2.10.1(a), (c) and (d) for reference purposes.

NOTE: Other information such as nominal compressed width and nominal compressed thickness may also be included on the tag.

2.2.10.2

Warnings

The following list of precautionary warnings shall also be provided as a minimum on the tag in English: (a)

Consult sling manufacturer or supplier for configurations not shown on the sling tag or a relevant load chart.

(b)

Do not use any sling that does not have a tag.

(c)

Inspect sling for damage before each use.

(d)

Do not use sling if there is any sign of a cut cover, snagging, heat or chemical damage, excessive wear, damaged seams, any other defects or presence of grit, abrasive materials or other deleterious matter.

(e)

Do not tie knots in sling.

(f)

Protect sling from sharp edges of load (e.g. steel sections).

(g)

Do not expose sling to temperatures above … degree Celsius. NOTE: Manufacturer to insert a safe maximum temperature. Information on safe temperatures is given in Clause 4.3.

(h)

Do not allow abrasive or other damaging grit to penetrate the fibres.

(i)

Keep away from … NOTE: Manufacturer to insert ‘acids’, ‘alkalis’, or ‘phenolic compounds’, etc. as applicable.

(j)

Consult with manufacturer’s recommendations, before exposing a sling to a chemical environment.

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AS 4497—2018

Company logo Company logo and/or Serial No.

information

W.L.L. 2000 kg

M = 0.8 M = 2.0

60° S.W.L. 3.4 TONNE

M = 1.7

90° S.W.L. 2.8 TONNE

M = 1.4

ROUND SLING LOAD CHART

M = 1.0

BASKET S.W.L. 4 TONNE

7 5 4 3

120° S.W.L. 2 TONNE

M = 1.0

SINGLE WRAP 45° DOUBLE WRAP 60° S.W.L. 2.76 TONNE

M = 1.38

Made from 100% Polyester

6 1 19 18 17 16

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CHOKE S.W.L. 1.6 TONNE

12 11 10 9

VERTICAL W.L.L. 2 TONNE

Date into service DATE

Mfr No Part No LENGTH

W.L.L. 2 TONNE SERIAL NO.

S l i n g s ar e m a d e f r o m 10 0 % p o l ys te r. E a c h s l i n g i s c l e ar l y l a b e l l e d w i t h t h e W. L . L . a n d t h e s afe t y fa c to r i s 7:1, A l l s l i n g s ar e c o l o u r c o d e d fo r i n c r e a s e d s afe t y. Fo r l i f t i n g r o u g h o r s h ar p l o a d s t h e u s e o f p r o te c t i ve s l e eve s i s re c ommend ed. Ro und s ling s ar e m a n u fa c t u r e d to AS 4 4 97

10 hints for safe lifting 1.

Consult s l ing load for conformation not shown.

. Do not use any s l ing that does not have a tag. 3. . Inspect s l ing for da mage bet ween each use. 4. . Do not use s l ing i f there i s any s ign of cut webbing, snagging, heat or chemical da mage, excessive wear, damaged seams, any other defects, or presence of grit, abrasive materials or other deterious mat ter. 5. . Do not t ie knots in s l ing. 6. . Protect s l ing f rom sharp edges of load. Use protective sleeves. 7. Do not expose s l ing to temperatures above 9 0 ° C 8. Do not allow abrasive or other da maging grit to penetrate the fibres. 9. . Consult with manufacturer ’s reco mmendations before immersing a s l ing in a chemical solution. 10. . Keep away f rom strong alkaline & phenolic compounds.

FIGURE 2.4 TYPICAL LABEL FOR A POLYESTER ROUNDSLING

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AS 4497—2018 2.2.10.3

Labelling

The marking in accordance with Clause 2.2.10 shall be given as follows: (a)

For single-leg slings, a label of a suitable material that is permanently attached to the woven cover of the sling by sewing.

(b)

For multi-leg slings, a durable and corrosion-resistant tag that is permanently affixed to the master link.

2.2.10.4

Colour and stripes

2.2.10.4.1

Label colour

The colour of the sling label shall be used to identify the fibre material, using the colour code in Table 1. TABLE 1

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FIBRE MATERIAL LABEL COLOUR CODE Fibre material

Colour

Nylon

Green

Polyester

Blue

Polypropylene

Brown

Aramid polyamide

Yellow

The colour of the label on slings manufactured from new or high performance synthetic fibres not listed above shall not be a colour from Table 1. 2.2.10.4.2

Sling capacity identification

Where the colour of the sling is used to identify its WLL, the colour code in Table 2 shall be used. Where stripes are used to identify the WLL of the sling the stripe code in Table 2 shall be used and the stripes shall be black. Where the colour of the sling is not used to identify its WLL the colour shall not be any of the colours listed in Table 2. Black stripes shall not be used unless to identify WLL. TABLE 2 COVER COLOUR AND STRIPE CODE FOR A SLING Working load limit t

Colour

No. of stripes

Violet

Green

Yellow

Grey

Red

Brown

Blue

Orange

>10

Orange

—

Bullivants | Page 462 of 692

AS 4497—2018

S EC TION

C AR E

AND

U SE

4.1 INTRODUCTION Roundslings support the load with a soft flexible contact surface that minimizes damage to the load, are light, soft and able to be stored in a compact way. However, they are more susceptible to physical and environmental damage than some other types of sling. This Section provides requirements and recommendations on roundslings to enable them to be used appropriately for the application. NOTE: See Appendix B for information supplied with enquiries and orders.

4.2 WORKING LOAD LIMIT (WLL) The sling shall have a WLL that will provide adequate capacity for the intended uses, taking into account the method of connection, slinging arrangement, environmental conditions and use, and the nature of the load to be lifted. 4.3 CHOICE OF APPROPRIATE SLING FOR THE APPLICATION

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The roundsling material shall resist degrading effects from the environment such as— (a)

moisture;

(b)

chemicals;

(c)

microbiological attack;

(d)

ultraviolet light;

(e)

sunlight;

(f)

heat; and

(g)

surface abrasion. NOTE: Because roundslings encourage a concentration of contaminants, they are generally not appropriate for use in chemical environments. Some applications may cause a degradation of the yarns, therefore further information should be obtained before use.

Relevant properties of roundsling materials shall be as follows: (i)

Nylon Nylon (i.e. polyamide) yarns generally have a high chemical resistance, but solutions of mineral or formic acids cause rapid weakening. NOTE: They should only be used within the temperature range of −40°C to 100°C.

(ii)

Polyester Polyester yarns generally have an extremely high chemical resistance, except to hot strong alkaline conditions. NOTES:

(iii)

Resistance of polyester to oils and common organic solvents is high.

They should only be used within the temperature range of −40°C to 100°C.

Polypropylene Polypropylene yarns are unaffected by most acids or alkalis, but are attacked by organic solvents such as white spirit, xylene. NOTE: They should only be used within the temperature range of −40°C to 80°C.

(iv)

Aramid polyamide Aramid polyamide yarns are very resistant to most types of chemical attack and to heat, but have low stretch characteristics. They shall only be selected for use after consultation with the manufacturer, as some applications may cause a degradation of the yarns. NOTE: They should only be used within the temperature range of −50°C to 130°C.

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AS 4497—2018

www.standards.org.au

TABLE 6 WORKING LOAD LIMITS (WLLs) Working load limits under general conditions of use t Straight lift Colour

Choked straight lift

Parallel basket

Basket hitch or 2, 3 and 4 legs slings α = 60°

α = 90°

α = 120°

Marked WLL α°

Loading factors

α°

0.8

1.73

1.41

Choke hitch or 2, 3 and 4 legs slings Single wrap α = max 45°

Double wrap α = max 60°

α°

1.38

0.8

1.7

1.4

1.38

Green

1.6

3.4

2.8

2.76

Yellow

2.4

5.1

4.2

4.14

Grey

3.2

6.9

5.6

5.52

Red

8.6

6.9

Brown

4.8

10.3

8.4

8.28

Blue

6.4

13.8

11.2

11.04

Orange

17.3

14.1

13.8

Orange

Greater than 10

Marked WLL × LF

Violet

AS 4497:2018

 Standards Australia

NOTE: The WLL applicable to each configuration is the marked WLL multiplied by the loading factor, L.

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AS 4497—2018

4.16 STORAGE Proper storage is essential for the prevention of deterioration and damage to slings. Slings should be stored in locations that have the following conditions: (a)

Clean and free from dirt and grit.

(b)

Dry and ventilated, to prevent condensation, i.e. not in receptacles that do not permit air circulation.

(c)

Provision for roundslings that have become wet in use, or as the result of cleaning, to be hung up and allowed to dry naturally. NOTE: Roundslings should not be excessively heated or otherwise force dried, i.e. not dried near a source of heat (such as in front of a fire or stove) or source of excessive heat.

(d)

Provision for off the ground storage, and without contact with any surface that may corrode during use—preferably on gratings, racks, stands or special coil pegs.

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NOTE: See Figure 4.18 for an example of sling storage rack.

FIGURE 4.18 EXAMPLE OF SLING STORAGE RACK

Slings should be stored away from the following: (i)

Ice, salt and other potential sources of cutting or abrasion.

(ii)

Direct sunlight and ultraviolet rays.

(iii)

Sources of potentially damaging heat, e.g. steam pipes, furnaces.

(iv)

Sparks from any source, e.g. welding, grinding etc.

Bullivants | Page 465 of 692

AS 4497—2018 (v)

Chemically degrading atmospheres, including damaging fumes.

(vi)

Chemically degrading materials, including liquids that may leak from containers.

(vii) Locations where mechanical damage is likely to occur, such as on or underneath racks containing heavy objects that could inadvertently damage the slings. 4.17 INSPECTION 4.17.1

Before each use

Every time a sling is to be used, the user shall inspect it for any signs of damage that could affect its safe use. Particular attention should be given to circumstances, locations and atmospheres that are likely to result in accelerated damage (see Clause 4.16). 4.17.2

Periodic inspection

At intervals of service of not more than three months the slings shall be inspected by a competent person. For heavily used slings the inspections should be more frequent. The inspection for any signs of damage shall cover all surfaces along the full length of the slings.

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The inspection shall take into account any concerns raised from an evaluation (see Clause 4.17.5). The competent person may recommend the sling be discarded, repaired or approve of the sling being returned to service (see Clause 1.3.1). Upon discard of slings, they shall be rendered unusable, e.g. removal of WLL tag or cut through. Inspections shall be carried out using the checklist shown in Appendix D to record defects and other comments. NOTE: See Clause 4.18 for discard criteria.

4.17.3

Periodic inspection records

For each sling, a record of every periodic inspection and the details of periodic inspections shall be kept. The record shall include the identity of each item, identity of inspector, the date of inspection and the outcome of the inspection. 4.17.4

Withdrawal from service

Slings shall be withdrawn from service immediately when any of the defects are found as listed in Clause 4.18. Any of the discard criteria listed in Clause 4.18 shall be observed. Defective conditions for slings shall be determined through, for example, observation of— (a)

unexplained lumps or thin regions inside the cover;

(b)

significant leaching in colour;

(c)

UV effects on cover, e.g. stiffness or significant colour changes;

(d)

illegible or missing labelling;

(e)

damaged or degraded covering;

(f)

damaged stitching; and

(g)

damaged end fittings or couplings.

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AS 4497—2018 4.17.5

Evaluation

Where a sling has been withdrawn from service as a result of a pre-use inspection it shall be— (a)

discarded if obviously unserviceable, not repairable and rendered unserviceable; or

(b)

set aside for a periodic inspection where there is uncertainty as to the serviceability or it is considered likely to be repairable.

4.18 DISCARD CRITERIA Any damage or faults in roundslings which may detract from the safe operation of the sling shall constitute a reason to discard the sling. When inspected in accordance with Clause 4.17.4 or the visual inspection checklist in Appendix D, slings shall be immediately discarded and destroyed when found to have damage or faults.

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NOTE: Examples of damage to slings that would render the sling unsafe for further use are shown in Figure 4.19.

Bullivants | Page 467 of 692

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AS 4497—2018

(a) Weld burn or heat damage

FIGURE 4.19 (in part) EXAMPLES OF DEMONSTRATING EXTREME DAMAGE TO ROUNDSLINGS

Bullivants | Page 468 of 692

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AS 4497—2018

(b) Cut and exposed fibres

FIGURE 4.19 (in part) EXAMPLES OF DEMONSTRATING EXTREME DAMAGE TO ROUNDSLINGS

Bullivants | Page 469 of 692

AS 4497—2018

FIGURE 4.19 (in part) EXAMPLES OF DEMONSTRATING EXTREME DAMAGE TO ROUNDSLINGS

4.19 REPAIRS Roundslings with damage to the core shall not be repaired. This includes slings with damage to the cover, which has exposed the core, as it is not possible to confirm there has been no damage to the core. Typical repairs may include replacement of a missing WLL tag, where the sling is sufficiently identifiable to ensure the correct label or tag is used, or repair of minor damage to the cover.

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Repaired slings shall be proof loaded and subjected to a periodic inspection, before return to service. Protective sleeves shall not be viewed as part of the load-bearing components of a sling. NOTE: These sleeves may be repaired without further proof testing.

Repaired slings shall be proof loaded, inspected and tagged before being returned to service. Testing and recording shall be carried out in accordance with Clause 3.3.1. 4.20 CLEANING A sling may require cleaning after exposure to certain contaminants, e.g. salt water or chemical exposure. Refer to manufacturer’s information for guidance on what contaminants may affect the sling. If a sling requires cleaning, refer to the manufacturer or supplier for suitable cleaning methods.

Bullivants | Page 470 of 692

AS 4497—2018

APPENDIX D

VISUAL INSPECTION CHECKLIST (Normative)

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NOTE: Refer to attached Bullivants Company Policy regarding "Synthetic items marked with Pen or Paint".

Bullivants | Page 471 of 692

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AS 4497—2018 www.standards.org.au

Breakdown of product

Tags, labels

Sling cover

Manufacturer's tags intact

•

Working load limit is legible

•

Tag is correct colour

•

Serial number is present

•

Standards mark

•

Nicks, holes, cuts

•

Dirt ingress

•

Grease/oil

•

Burns, chemical damage

•

Colour change

•

Hardening of internal fibres

•

If you can see internal fibres the sling must be condemned

•

Thickening of the sling or presence of grit or dirt may indicate wear

•

Colour change

•

Any damage to a protective coating or sleeve can allow abrasive grit easier access to the sling

•

Broken stitching

•

Cuts

•

Eye fibre wear

•

Chemical, heat marks/burns

•

Any wear, cracks, gouges, cuts stretch etc.

•

(Inspect fittings in accordance with the appropriate Australian Standard and complete appropriate inspection report)

Sling internal wear Protective coating or sleeve

Sling lifting eyes (where formed)  Standards Australia

Any attached fittings

Required work/result Action

Failed

Passed

AS 4497:2018

•

List all observations

Internal fibres

Points to be inspected

Bullivants | Page 472 of 692

Bullivants | Page 473 of 692

1. SCOPE

To establish a process for evaluating the affect of paint and marker pens on webbing slings, roundslings, harnesses, lanyards and similar products.

2. REFERENCES • • • • • • •

ISO9001 - Quality Management Systems – Requirements AS 1353 – Flat synthetic webslings AS 4497 - Round slings synthetic AS 1891.4 - Industrial fall arrest systems & devices :Care and Use Bullivants Visual Inspection checklist – Belts and harnesses Bullivants Visual Inspection checklist – Flat webbing slings Bullivants Visual Inspection checklist – Synthetic Roundslings

3. DEFINITIONS • Equipment as stated in standards above in section.2

4. SAFETY • •

Onsite work will be subject to site safety rules which should be ascertained before work commences. Additional safety requirements will be noted in the body of the checklist where necessary.

Bullivants | Page 474 of 692

6. PROCEDURE

All synthetic items (lifting or height related) shall be inspected as per the relevant Australian Standards and the company visual inspection checklists. When visual inspection shows that an item has been marked directly on the fabric with a permanent marker or paint the following steps shall be taken. (Although round sleeve covers are non-load bearing it is possible that the contaminant could penetrate the cover and damage the internal fibres). Signs of chemical attack e.g. local weakening or softening of the material allowing fibres to be plucked or rubbed off (or in extreme cases reduced to powder) are justification for immediate removal from service. It is the further policy of the Company that even if there are no visible signs of the effects of markings known to have been made on the item it shall still be placed “Out of Service” and placed aside in a designated area. (The reason for adopting this policy is that once the ink or paint is dry there is no way to determine if it is water based(acceptable) or Xylene or Acetone based which has been shown to be capable of a 50% reduction in fibre strength) A notation shall be made in the lifting gear register and/or on BEAM that the item has been marked with permanent or paint marker . Advise the customer that using permanent or paint markers on webbing is not considered good practice and could cause damage to the webbing fibres as detailed above If the customer wants to accept responsibility and allow them back into service , please note this site policy on the “Service Agreement” then get the customer to ‘sign off’ the agreement or site memorandum. If any problems arise consult your supervisor or the Bullivants Training team. Discuss with your customer any site specific rules that may apply and over-ride the relevant standard. Remember if any doubt as to the items integrity or fit for purpose, please tag “Out of Service” and seek a second opinion. Then reissue for use or discard from service. Complete the visual inspection as per the Bullivants Visual Inspection checklists and close out the work. Complete sign off of the site service agreement and depart from site.

Bullivants | Page 475 of 692

I …………………………………hereby testify that I have read and understood this procedure dated …………...….and I…………………………... do hereby on the behalf of Bullivants Pty Ltd, testify that I have tested the above signatory on this day………………..and the signatory has satisfactorily understood and met the requirements of this procedure.

Bullivants | Page 476 of 692

Bullivants | Page 477 of 692

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AS 4722:2018

3.5 Passenger ropeway

A powered ropeway used for transporting, m a horizontal or inclined pl ne, passengers moved by carriers that are-----,(a)

attached to or supported by a moving rope; or

(b)

attached to a moving rope but supported by a standing rope or other overhead structure.

, II

NOTES: The term includes the prime mover and any transmission machinery, supporting structure and equipment. It does not include equipment such as cog railways, cablecars running on rails, equipment such as flying foxes, or elevating systems for vehicles or boat-style carriers associated with amusement rides such as log or boat flume rides . 2 This Standard uses the terms 'rope' and 'ropeway' in preference to the terms 'cable' and 'cabteway' .

4 CANADIAN REFERENCED DOCUMENTS

References in CSA Z98-l 4 shall be replaced by Australian Standards or other relevant equivalent documents some of which are indicated in Clause 5 for the particular Clause in which they are referenced unless another document is called up by legislation. NOTE: Documents that are referenced in CSA Z98-14 but are not specifically mentioned in Clause 5 are applicable in Australia.

5 VARIATIONS TO CANADIAN REQUIREMENTS

Passenger ropeways and passenger conveyors shall conform to CSA Z98-l 4, varied in accordance with this Clause. NOTES: 1 Additional information is provided on certain clauses to assist in the interpretation and implementation of the requirements in CSA 298-14. Such information is indicated by the word 'Commentary' preceding the text. 2 Any clause reference in the. following table is to CSA 298-14 unless specified otherwise .

CSA Z98-14 clause reference

Australian variation Commentary: The term 'designer' should be interpreted in context; for example, in Clause 4.2.1 the term may refer to the designer of the alteration rather than the original designer of the ropeway.

When applying CSA Z98-14, it should be noted that the term 'drive' is 1 used for the motor alone, whereas in Australia the term is usually used to refer to the prime mover (motor or engine) and associated drive train components such as the gearbox. 'Drive' may also be used to indicate the electric motor controller, such as a VFD, in Australia. The term 'engineer' is used in CSA Z98-14; the term 'competent person' should be substituted for Australian applications. 4.3.1

Add the following:

(r)

lightning risk.

www.standards.org.au Bullivants | Page 478 of 692

AS 4722:2018

CSA Z98-14 clause reference

11.3.1

11.3.2.2 11.4.1 11.4.4 11.5.2

11.6.1.1

11.7.4.2 11.7.4.3

11.7.4.5

Australian variation

I Commentary: Similar Australian Standards to CSA G4 and <CAN/CSA-G12 are AS 3569 and AS 2841 respectively. There are als1 International Standards that could be used as equivalents.

Commentary: A maximum factor of safety for haul rdpes has been included to ensure haul rope wires remain in tension and are not subjected to cyclical compression/tension loading.

Commentary: 'Regular lay' is the same as 'ordinary lay' in Australian terminology.

Add at end of sentence 'or an appropriate grade of stainless steel'. Replace with the following:

Testing shall be completed m accordance with CAN/CSA-G4 or equivalent.

Commentary: Similar Australian Standards are AS 3569 for ropes and AS 1394 for wires. EN 12385-9 should be consulted for testing of shaped wire rope.

Commentary: A splice certificate in accordance with Clause 11.14 is required by Clause 11.13 for inclusion in the wire rope log. The recommendations and methodology in AS 2759 relating to long splicing should be consulted for guidance: however, the proportions given in ' CSA 298-14 take precedence.

Commentary: AS 2759 provides current Australian practice for poured sockets.

Reolace the term 'qualified person' with 'competent person'. 1

Replace the text of Item (a) with 'chemical analysis of the socketing material or the material standard reference;'

Add new Item (f) as follows:

(f)

date of installation.

11.7.4.6 (new) Add new Clause 11.7.4.6 as follows: 11.7.4.6 Mechanical sockets

For each mechanical socket, a report shall be provided containing as a minimum(a)

(b)

Standards Australia

the initial value for the slippage monitoring dimension;

(c)

the type of lubrication, if applicable;

(e)

the date of installation.

(d) 11.7.5.1

identification of the socket manufacturer;

the name and signature of the person who installed the socket; and

NOTE: A samvle mechanical socket report.form is included in Avvendix KA.

Replace with the following:

The use of wire rope clips and thimbles in loadbearing situations shall be limited to tensioning ropes and guys. www.standards.org.au Bullivants | Page 479 of 692

AS 4722:2018

CSA Z98-14 clause reference 11.7.5.2

Australian variation

Replace with the following: Wire rope clips shall comply with AS 2076 or equivalent.

11.7.5.3

Replace with the following: Wire rope clips and thimbles shall be installed in accordance with AS 2076.

11.7.5.5

Replace with the following: Torque values and retightening procedures shall be in accordance with the instructions of the wire clip manufacturer or AS 2076 in the absence of the manufacturer's instructions.

11.8.1 and 11.8.2

Commentary: The first magnetic rope test (MRT) is carried out to establish a baseline record of the rope condition.

11.8.3

Replace Item (a) with the following: 'Magnetic rope testing (MRT) conducted to fulfil the requirements of this Clause (11.8.3) shall be carried out by a competent person in accordance with the requirements of AS/NZS 4812, excluding Clause 2.4.3 (frequency) for conducting non-destructive examinations.'

Replace Item (d)(iv) with the following: 'condition of splices and repairs, including dimensions over tucks;'

Commentary: In relation to Item(d)(ix), AS/NZS 4812 advises that the relationship between loss of metallic area (LMA) and the loss of actual breaking force may not be necessarily linear or fixed. Conversion factors from LMA to loss of breaking force vary with the type of deterioration in the rope. Care should be taken when attempting to convert LMA into loss of breaking force, especially if there is corrosion within the rope. In extreme cases, it has been found that loss of breaking force can be six times the indicated LMA. 11.8.6

Replace 'an engineer' with 'a competent person' .

11.8.7

Replace with the following: For reversible ropeways with spliced haul ropes, an MRT of the haul rope shall take place at yearly intervals unless experience justifies a different interval. Any such interval change shall be as specified by the manufacturer or designer of the system or by a competent person.

11.10.1

www.standards.org.au

Commentary: The intention is to break the wire in such a manner that it cannot interfere with line equipment. It is usual that the break should be induced in the valley.

AS 4722:2018

CSA Z98-14 clause Australian variation reference ------+----------------�---------'------11.11.2

Replace Item (d) with the following:

( d)

diameter reduction to below(i)

94% of the actual diameter measured after 50 h of operation;

(ii)

96% of the nominal diameter if the 50 h diameter is not available; or

(iii) for either circumstance, a percentage (but not less than 90%) of nominal diameter specified by both the lift and rope manufacturer based on their assessment of the rope and the usage.. Commentary: The grips may need consideration for any reduction of diameter to 90% nominal rope diameter. 11.11.5.1, Table 7

Commentary: Table 7 specifies limits for loss of cross-sectional area in terms of percentage loss over certain reference lengths. To obtain the loss of cross-sectional area over the reference length, it is necessary to add together all the damages (in terms of loss of metallic cross-section) that occur in that reference length. A damaged wire should be counted only once. The first reference length is six times the nominal diameter of the rope and is used to assess local damage. The second reference length is 40 times the nominal diameter of the rope and is used to assess the real loss of breaking strength of the wire rope. It is based on what is called the 'extinction length'. This is the distance after which the effect of a broken wire is considered to have disappeared (due to stranding effect and friction). The third reference length is 500 times the nominal diameter of the rope and is used to assess the general condition of the wire rope.

11.12.1 11.12.3

Add to the end of the sentence 'to the satisfaction of the rope manufacturer erson.'

11.12.5

Rep

11.13

Replace Item (b) with 'copy of documents provided in accordance with Clause 11.5.1;'

Replace Item (d) with 'splicing certificate for each splice and details of each repair [see also Clause 11.14 and Item 11.11.6(e)];'

Replace Item (t) with 'record of visual inspection in accordance with I Clause 11.8.4;' Replace Item (g) with 'report of wire rope inspection in accordance with Clause 11.8.3;'

4 5 11.14

Replace Item (i) with 'documentation of end attachment, e.g. a certificate as per Appendix K.'

Replace Item c with 'rope dimension measurements over tucks;'

www.standards.org.au Bullivants | Page 481 of 692

AS 4722:2018

32 I

CSA Z98-14 clause reference

Australian variation Where the required inspections are not detailed by th·s Standard or stipulated by the ·designer, manufacturer, supplier or the relevant regulatory authority, the content and detail of annual inspection procedures (including but not limited to, preventative mainte?ance, annual inspections, return to service and commissioning) shall be established by a competent person and due regard shall be given to the history of the particular installation and the state of knowledge concerning related and similar installations. Commentary: It should be noted that the term 'maintenance' is used in CSA 298-14 to cover inspection, testing and maintenance requirements. Clause 12.9 relates to particular inspections, tests and procedures, which form integral elements in a required preventative maintenance program.

12.13

Replace the text of Clause 12.13 with the following: The manufacturer's brake test procedure and appropriate test values shall be readily available. Brake testing shall be carried out at least annually and the test results recorded.

12.16.10

Replace the text of Clause 12.16.10 with the following: The tests specified in Clause 12.16 shall be preceded by a sufficient period of operation with empty carriers to determine the proper function of all systems and make any necessary adjustments.

12.18.1.1

Add 'or a competent person' after 'manufacturer'.

12.18.1.2

Commentary: The following Australian Standards are available for use when specifying non-destructive testing: (a)

For visual inspection, AS 3978.

( b)

For magnetic particle inspection, AS 1171.

(c)

For dye penetrant inspection, AS 2062.

(d)

For ultrasonic testing, AS 1065, AS 1710, AS 2207, AS 2452.3, AS/NZS 2574 or AS 2824.

(e)

For eddy current inspection, AS 2084 or AS 4544.

(f)

For radiographic inspection, AS 2177, AS 2452.1, AS 3507.1 or AS 3507.2. I

12.18.I.3

Replace 'qualified persons' with 'competent persons'.

12.18.1.4

Add: Specified periodic NDT (non-destructive testing) and any ad hoc NDT shall be documented by the tester. Such records shall be kept by the owner/operator and referenced in the log for the ropeway. Test reports shall clearly identify all items tested and, where applicable, the locations of the test on each item. Reports shall include at least-

(a)

the identification of the ropeway;

(b)

the name(s) of the test personnel;

(c)

the date and location of the test;

(d)

the methodology of the test; www.standards.org.au Bullivants | Page 482 of 692

AS 4722:2018

CSA Z98-14 clause reference

Australian variation

II,It! I

(e)

the item(s) and location(s) tested identified by use of the serial numbers or use of drawings, sketches or photogrfphs; and

(t)

the result of the test and, where applicable, the criteria for judgement.

NOTE: Where the criteria for judgement are set by the designer, manufacturer or a competent person, a copy of the instruction or a reference to it should be aooended.

12.18.2,2

Replace 'an engineer' with 'a competent person'.

12.18.3.1

ReJJlace 'engineer' with 'competent person'.

12.18.3.2

In Item (a), replace 'the manufacturer's requirements' with manufacturer's or a competent person's instructions.'

13.5.1

Add the following:

'the

For situations where an operator always travels in a cabin as in Clause 13.5.l (e), the operator may serve as the loading and unloading station attendant. 13.7.3 (new)

Add new Clause 13.7.3 as follows: 13.7.3 Bushfires and extreme weather conditions Procedures shall be developed and implemented to detect the approach of bushfires and extreme weather conditions in sufficient time to implement measures required to maintain the safety of passengers and equipment.

13.16.1 and 13.16.3

Add the following:

13.16.2.4(e)

Replace 'Cordage Institute CI 1500' with 'EN 1891'.

13.16.2.4(g)

Delete Item (g) and replace with the following:

When the evacuation plan involves use of emergency services, they should be involved in the preparation of the plan and should be accorded every opportunity to undertake training or drills at least once per year for continuously operating installations and prior to each opening for seasonal operations.

Emergency services and nominated personnel shall use either the provided evacuation equipment or their own height safety equipment for evacuation provided-

(i)

it meets or exceeds the same standards as the rest of the evacuation equipment;

(ii)

it is maintained and inspected according to manufacturers' recommendations;

(iii) it is compatible with other equipment used in the evacuation plan; and (iv) it will be available when required.

www.standards.org.au

Standards Australia Bullivants | Page 483 of 692

AS 4722:2018

APPENDIX KA

EXAMPLE MECHANICAL SOCKET REPORT (Informative) Ropeway name:

MECHANICAL SOCKET REPORT

Ropeway reg.no:

Ropeway type:

Manufacturer:

Owner:

□ □D

D D D D

Socket lo<;ation/rope type

Track rope

Which one (e.g. East, West, A, B ... )

Haul rope

Which one (e.g. Upper, Lower... )

Tail/counter rope

Which one (e.g. Upper, Lower... )

Tensioning rope

Which one (e.g. East, West, A, B... )

Rigging rope

Counterweight tag line

Other

I :=======�

I!========::::::

Specify:

Socket type:

Lubricant applied:

Location

::::I=·======�

Note any reference measurement:

Installation data

Location:

Measurement:

Information regarding procedures used:

Remarks:

Date:

Location:

Signature of Installer:

www.standards.org.au Bullivants | Page 484 of 692

AS 4797—2009

Australian Standard® Stainless steel chain for lifting purposes

Bullivants | Page 485 of 692

AS 4797—2009 TABLE 1 DIMENSIONS OF LINKS millimetres 1

Material size Nominal chain size Nominal d

Link dimensions

Limits (see Figure 2) dm

Inside length p

Max. Min.

Max.

Min.

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Weld protrusion

Width Outside Inside max. min.

Max. from centreline

(3.09dn) (2.91dn) (3.5dn) (1.25dn) (0.6dn) dn

Type 1

Max.

Type 2

Max.

(1.1dn) (1.35dn) (0.1dn)

5.0

5.2

4.8

15.4

14.6

17.5

6.3

3.0

5.5

6.7

0.5

6.0

6.2

5.8

18.5

17.5

21.0

7.5

3.6

6.6

8.1

0.6

7.0

7.3

6.8

21.6

20.4

24.5

8.8

4.2

7.7

9.4

0.7

8.0

8.3

7.7

24.7

23.3

28.0

10.0

4.8

8.8

10.8

0.8

10.0

10.4

9.6

30.9

29.1

35.0

12.5

6.0

11.0

13.5

1.0

13.0

13.5

12.5

40.1

37.9

45.5

16.3

7.8

14.3

17.5

1.3

16.0

16.6

15.4

49.4

46.6

56.0

20.0

9.6

17.6

21.6

1.6

FIGURE 1 LINK

6.2 Welding Chain shall be manufactured by electric welding and finished to the required dimensions (see Figure 2 and Table 1). The links and welds shall not show fissures, notches or similar faults that are detrimental to the chain. The thickness of the weld material shall be not less than the diameter of the material of the link. For smooth welded chain (Type 1), fins caused by welding shall be removed and the weld shall be smoothly finished all around. For asymmetric welded chain (Type 2), the fins caused by welding shall be removed from the outside of the link surface, leaving the projections on the inside and thus forming a smooth exterior asymmetric weld. The positioning of the weld at the centre of the straight barrel and the tolerances imposed on protrusions at the weld should provide the required clearances. The chain should be surface-treated to remove residual contamination and discolouration, which would otherwise affect corrosion resistance.

Bullivants | Page 486 of 692

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AS 4797—2009

FIGURE 2 MATERIAL AND WELD

6.3 Links inserted in the course of manufacture Links inserted in a length of chain during manufacture shall be of the same material and be processed to provide dimensional and mechanical properties complying with those specified for the adjoining links. 6.4 Kinking Chain should be designed so that it will not kink or lock in service. 6.5 Chain finishes Chain shall be supplied in one of the following finished conditions: (a)

Electropolished.

(b)

Pickled and/or passivated to ASTM A380 or equivalent.

(c)

Mechanically polished or cleaned.

Where specified by the purchaser (see Appendix A) chain may be supplied in the as-welded condition (no subsequent surface treatment). Electropolishing and passivation shall be conducted by the manufacturer prior to proof-testing. NOTE: Links of finished chain are in a metallurgical condition that could be adversely affected if subsequently heated, coated or otherwise processed.

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AS 4797—2009 6.6 Visual examination Visual examination shall be conducted after proof-testing, to detect manufacturing faults such as incomplete or misaligned welds, gouges, twists, nicks or inadequate surface treatment. Defective chain links shall be discarded. 7 MARKING 7.1 General Each length of chain shall be permanently and legibly marked at intervals of not more than 20 links, the marking being either raised or indented. Where the marking is indented, the marks shall be without sharp edges and the depth and location of the marks shall be on the barrel opposite the weld, and shall not reduce the strength of the chain. 7.2 Information The following information shall be marked: (a)

Manufacturer’s identification.

(b)

Material grade (e.g., 304, 316).

(c)

Quality grade (i.e., 5 or 50).

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8 MECHANICAL PROPERTIES 8.1 Permanent deformation Each complete length of chain shall be capable of supporting the relevant proof-test force specified in Appendix D, without sustaining permanent deformation which may adversely affect its performance. 8.2 Strength A destructive test shall be undertaken on one tensile test sample for every 200 m of chain comprising the lot. The test sample shall achieve the minimum break force and the minimum total elongation, applied under the conditions and forces specified in Appendix D. Where a chain fails to meet testing requirements, retesting shall be undertaken in accordance with Appendix D. 8.3 Ductility Ductility shall comply with the requirements of Appendix F. 9 TESTING OF MECHANICAL PROPERTIES Compliance of each design with the requirements of Clause 8 shall be demonstrated. NOTE: Means for demonstrating compliance with this Standard are given in Appendix E.

10 PROOF-TESTING 10.1 Proof force Each complete length of chain shall be subjected to a proof force of not less than that specified, under the conditions specified in Appendix D. 10.2 Requirements The complete length of chain shall withstand the application of the proof force, without sustaining damage that may affect its intended function or safety, and shall be free from visible deleterious permanent deformation. A competent person (see Clause 4.3) shall be satisfied that these requirements have been met.

Bullivants | Page 488 of 692

AS 4797—2009 10.3 Test certificate The proof-testing shall be recorded on a test certificate, which shall bear the following information: (a)

Nominal size of chain.

(b)

Material grade.

(c)

Quality grade.

(d)

Finish.

(e)

Quantity.

(f)

Batch or lot number.

(g)

Proof force.

(h)

A declaration that the chain complies with this Standard.

(i)

The name and address of the manufacturer or supplier.

(j)

The name and address of the testing establishment.

(k)

An approved signatory.

(l)

Type of certificate (e.g., NATA, certifying authority, supplier).

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NOTE: The manufacturer should retain the original test certificate for not less than 10 years.

Bullivants | Page 489 of 692

AS 4797—2009

APPENDIX C

CARE AND USE (Normative) C1 WORKING LOAD LIMIT (WLL) Chain shall not be used in a manner that will exceed the WLL of the chain for the particular conditions of use. The WLL for each chain is based on a design factor of 4. General conditions of use are equivalent to a group classification for crane mechanisms of M3, as specified in AS 1418.1. C2 STRESS CORROSION CRACKING Austenitic stainless steels can be subject to stress corrosion cracking (SCC) in some environments, particularly in chloride containing waters above 55°C. This results in relatively fast propagating fine cracks that can be difficult to identify during a visual or dye penetrant inspection. The user should seek advice from the manufacturer for their specific application.

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NOTE: Austenitic stainless steels should not be used to support loads above chlorinated indoor pools as they may fail due to SCC at ambient temperatures. This prohibition does not apply to outdoor pools.

C3 EFFECTS OF HOT ENVIRONMENTS The strength of all grades of chain is adversely affected by excessively elevated temperatures. Where the operating temperatures are likely to exceed 200°C, users should contact the manufacturer for the required reduction in working load limit. C4 LOW TEMPERATURE Austenitic stainless steels are suitable for use at cryogenic temperatures (i.e. below −150°C). C5 HEAT TREATMENT

Chain in its finished condition should not be heat-treated. C6 CORROSIVE ENVIRONMENT Stainless steel chain is suitable for use in many corrosive environments, provided a suitable material type is chosen. Stainless steel is prone to pitting corrosion under surface contaminants. A clean and smooth surface provides optimum corrosion resistance. Regular cleaning and inspection should be conducted. NOTE: AS 4673 provides guidance of the suitability on various grades of stainless steel for specific environments.

C7 ELECTROPOLISHING Stainless steel chain should not be electropolished, except by the manufacturer.

Bullivants | Page 490 of 692

AS 4797—2009 C8 EXTENDING THE USEFUL LIFE The useful life of chains may be maximized by observing the following: (a)

(b)

Care: (i)

Regularly wash chain, preferably with soap or mild detergent and warm water followed by rinsing with clean cold water.

(ii)

Store chain in clean dry place.

Use: (i)

Ensure that chain is free of any significant damage or wear.

(ii)

Ensure that chain is evenly loaded.

(iii)

Ensure that chain is free of twists and knots and is protected from any sharp corners.

(iv)

Ensure that chain is loaded gradually without shock.

(v)

Avoid crushing chain.

C9 INSPECTION

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It is important to regularly inspect chain; in particular, observing the following: (a)

Chain should be cleaned before it is inspected.

(b)

Every chain link should be individually inspected for any signs of wear, twisting, stretching, nicks, cracks, gouging or pitting corrosion.

(c)

Any worn links should be measured to determine the degree of wear, which should not exceed 10% of its original dimension in any plane.

(d)

Chain links having any defects that are likely to affect chain rating should be clearly marked to indicate rejection, and the chain withdrawn from service and destroyed.

(e)

A chain inspection record should be provided for each chain.

(f)

The results of each inspection should be entered on the chain inspection record.

Bullivants | Page 491 of 692

AS 4797—2009

APPENDIX D

TEST FORCES AND CONDITIONS FOR THEIR APPLICATION (Normative) D1 TENSILE TEST SAMPLE (a)

(b)

A tensile test sample shall contain not less than the following number of links: Nominal size mm

Number of links

≤6 >6 ≤ 17

9 7

Gauge length shall be determined and recorded.

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NOTE: Clause 4.7 defines gauge length and Figure D1 below provides guidance.

FIGURE D1 GAUGE LENGTH

D2 CONDITIONS The following conditions apply to the application of test forces to a chain: (a)

The testing machine shall be calibrated in accordance with AS 2193. It shall be capable of Class A results when testing mechanical properties (see Clauses 8 and 9) and Class C results when proof-testing (see Clause 10).

(b)

Except for proof-loading, manufacturing processes shall be completed.

(c)

A test sample shall be engaged in the tensile testing machine in a manner such that the load acts along the axis of the chain to simulate the normal operating condition without twist and without damage to the engaging links. The specified minimum proof force shall be applied. After the load has been released, the gauge length of the test sample shall be determined [see Paragraph D1(b)]. A gradually increasing load shall then be applied until the chain achieves the minimum break strength and minimum total elongation specified in Table D1. The elongation may be determined in accordance with Appendix F.

Bullivants | Page 492 of 692

AS 4797—2009 Should any test sample fail to fulfil the test requirements, two further test samples may be selected from the sample lot of chain for retesting. The lot complies when the original tensile test or both the additional retests are satisfactory. (d)

After satisfactory completion of Item (c) above, the balance of the lot shall be proof-tested with a force that is not less than the relevant one specified in Table D1, in a tensile testing machine, in such a manner that the load acts along the axis of the chain to simulate the normal operating condition, without twist and without damage to the engaging links. A greater proof force may be applied, provided it does not impair the safety, strength or working life of the finished chain. TABLE D1 TEST FORCES WLL

Manufacturing proof force

Minimum breaking force

tonne

0.5

0.75

1.0

1.25

2.0

3.2

133

5.0

100

201

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Nominal chain size d (mm)

NOTES: 1

The mean stress in the chain at minimum breaking force is 500 MPa.

The WLL is based on a design factor of 4.

The manufacturing proof force is 2 × WLL × 9.81 kN.

The minimum elongation shall be 20%.

Bullivants | Page 493 of 692

y nl O pl e Sa m

Bullivants | Page 494 of 692

AS 4797—2009

APPENDIX F

DETERMINATION OF ELONGATION (Normative) F1 GENERAL The total elongation, as defined in Clause 4.22, is most effectively determined with autographic instrumentation (see Paragraph F4); however, alternative procedures, which do not require such equipment, are detailed in Paragraphs F2 and F3. The procedures in Paragraphs F2 and F3 require a greater elongation capability; chain that may fail to comply with either of these procedures may exhibit an adequate elongation when tested by means of autographic instrumentation. F2 DETERMINATION OF PLASTIC ELONGATION OF BROKEN TEST SAMPLE

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The total elongation (plastic plus elastic) of chain always exceeds the plastic elongation by the elastic elongation. Where the plastic elongation alone is measured and found to be no less than that specified in Table D1 (see Note 4 of Table D1), then the chain shall be regarded as complying with this Standard. The intent of the procedure is to determine the total pitch of the gauge length in accordance with Appendix D, Paragraph D2(c). The test sample shall be loaded gradually and smoothly until breakage occurs, as shown in Figure F1. The plastic elongation, expressed as a percentage, shall be determined as follows: ⎛ N (A + B ) ⎞ Plastic elongation (%) = ⎜ − 1⎟ ×100 ⎝GL(N − 1) ⎠

where

= number of links in test sample

NOTE: Figure F1 below depicts 9 links, 7 of which comprise the gauge length.

GL = gauge length NOTE: See Appendix D, Paragraph D2(c)

The maximum force obtained during this procedure shall be the actual breaking force.

Bullivants | Page 495 of 692

AS 4797—2009

FIGURE F1 STRETCHED SAMPLE AFTER BREAKAGE

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F3 DETERMINATION OF TOTAL SAMPLE

ELONGATION OF UNBROKEN TEST

This procedure shall be used to determine the total pitch of the gauge length in accordance with Paragraph D2(c), Appendix D, and, with the tension maintained between 8% and 12% of the specified minimum proof force, to mark the position of the moving head. The load shall be increased, gradually and smoothly, until the head has moved the required minimum total elongation, this movement being: Specified minimum total elongation (%) × 0.01 × GL (see Paragraph F2).

Should the specified minimum break load not have been reached when the elongation achieves the specified minimum, then the loading shall be continued until the specified minimum breaking load is attained. NOTE: This procedure presumes no significant elastic strain between the points of engagement of the sample and the movement indicator. Where such strain is significant, it is to be determined and appropriate allowance made.

F4 DETERMINATION OF TOTAL ULTIMATE ELONGATION The determination of total elongation using autographic instrumentation produces a load/extension diagram similar to that shown in Figure F2. NOTE: Where recorded extension is that of the moving head, appropriate allowances are to be made for the elastic strain of the test sample holding system where such strains are found to be significant.

The elongation shall be based on the total elongation at fracture (E) shown in Figure F2. This shall then be expressed as a percentage of the gauge length [see Paragraph D2(c), Appendix D] of the sample where: E ×100 Elongation (%) = GL where E

= total elongation

GL = gauge length

Bullivants | Page 496 of 692

AS 4797—2009

FIGURE F2 TYPICAL LOAD/EXTENSION DIAGRAM

www.standards.org.au

AS/NZS 4812:2003

AS/NZS 4812

Australian/New Zealand Standard™ Non-destructive examination and discard criteria for wire ropes in mine winding systems

Bullivants | Page 498 of 692

AS/NZS 4812:2003

(k)

The relationship between LMA and loss of actual breaking force may not be necessarily linear or fixed. Conversion factors from LMA to loss of breaking force vary with the type of deterioration in the rope. Care should be taken when attempting to convert LMA into loss of breaking force, especially if there is corrosion within the rope. In extreme cases, it has been found that loss of breaking force can be six times the indicated LMA.

2.3 CALIBRATION Where any of the following instruments are used during examinations, they shall be calibrated and tested, where applicable, in accordance with any relevant Australian Standard:

(a)

Straight edge or other flatness indicator.

(b)

Measuring tape or lay length ruler.

(c)

Vernier callipers or micrometer.

(d)

Monocular microscope with graduated reticule (see AS 3978).

(e)

EM instrument that has traceable calibration records and has been calibrated on an annual basis or as recommended by the manufacturer.

2.4 ROPE EXAMINATIONS Accessed by Wesfarmers Industrial and Safety Ltd on 09 Mar 2018 (Document currency not guaranteed when printed)

2.4.1 General Rope examinations shall include the following sequential processes:

(a)

Non-destructively testing a rope using a magnetic instrument, as specified in Clause 2.4.6.

(b)

Visually examining the areas where non-destructive testing has indicated anomalies to exist, as specified in Clause 2.4.7.

All rope measurements and appropriate comments shall be recorded. 2.4.2 Reference values of new rope Examinations of rope allow changes to be observed, by comparing the rope to an examination made when it was new. After a newly installed rope has been bedded in, but before the rope has aged, deteriorated or been damaged in any way, the rope shall be non-destructively tested and the rope diameter and the rope lay length at datum locations shall be measured. Rope diameter shall be measured in accordance with Clause 2.4.8. The locations of these measurements shall be recorded for future reference. Allowance shall be made for rope crops, which affect the locations of these positions. 2.4.3 Frequency The frequency of NDEs shall comply with any relevant requirements of the statutory authority. Testing frequencies should be based on expected rope life operating cycles, operating conditions and rope constructions. It is recommended that NDE be conducted at frequencies not exceeding the following periods or one sixth of the expected rope life:

(a)

Friction winder head ropes ......................................................................... 6 months.

(b)

Friction winder balance ropes ................................................................... 12 months.

(c)

Guide/rubbing ropes ................................................................................. 30 months.

(d)

Drum winding ropes ................................................................................... 6 months. COPYRIGHT

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AS/NZS 4812:2003

2.4.9.2

Test report

A detailed test report shall be supplied to the customer. The test report shall include the following information:

(a)

Customer name.

(b)

Location.

(c)

Details and identification of rope tested, including reference to original test certificate.

(d)

Date of rope installation.

(e)

Date of testing.

(f)

Test report number.

(g)

Test method used.

(h)

Test equipment used.

(i)

Interpretation of NDT and visual inspection results.

(j)

Statement on rope condition with respect to the discard criteria given in Section 3.

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NOTE: A method for classifying corrosion and wear is given in Appendix E.

(k)

A graph showing the progressive deterioration of the rope (e.g., LMA, wire breaks, percentage loss of diameter), incorporating the results of any previous relevant tests, preferably in graphical form. A typical graphical report is shown in Figure 2.

(l)

Whether the wire rope can be maintained in operation, with or without special precautions, or if it should be discarded immediately, taking into account its function.

(m)

Reference to this Standard.

(n)

Identity of the examiner.

(o)

Date of issue of report.

NOTE: Test reports are enhanced if a shaft layout similar to the example is shown in Figure 3 is provided.

Test reports of any examination shall be retained until the rope is retired from service and for any additional period specified by an appropriate authority. NOTE: The report and charts should be retained by the testing authority for the life of the installation.

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AS/NZS 4812:2003

SECTI ON

R OP E

D IS C AR D

C RI T ERI A

3.1 GENERAL Excessive rope stretch that is detected by a rope management system may be a reason for the rope to be discarded. Where a loss of breaking force is indicated by NDE, such a loss should be verified by a destructive test of that section of the rope, after removal of the rope. 3.2 WINDING ROPES, INCLUDING BALANCE ROPES The intent of the discard criteria below are to prevent the use of a rope with a loss of breaking force exceeding 10%. Ropes deteriorate due to the cumulative effects of wear, corrosion and broken wires. It is recommended that an assessment of these effects be made by a competent person and fitness for further service be considered.

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Winding ropes, including balance ropes, shall be discarded where any of the following criteria apply:

(a)

Statutory life The service has reached the maximum service life specified by the applicable statutory authority.

(b)

Uniformly distributed broken wires Uniformly distributed visible broken wires in a rope within one rope lay cause a loss of effective rope metallic area of more than 8% (see Clause 1.3.16).

(c)

Non-uniformly distributed broken wires Non-uniformly distributed visible broken wires in a rope within one rope lay cause a loss of effective rope metallic area of more than 5%.

(d)

Broken wires in one strand lay length Visible broken wires in one strand within one rope lay result in a loss of effective rope metallic area of more than 3%.

(e)

Broken wires in a strand The number of visible broken wires in any strand within one rope lay is more than 40% of the total number of outer wires in the strand.

(f)

Broken wires in adjacent lay lengths The number of identifiable broken wires in five adjacent rope lay lengths is double that permitted by Items (b) and (c) above for one rope lay length.

(g)

Broken wires in valleys There is more than one visible broken wire within a rope lay due to in-service effects between strand-to-strand contact points in a rope valley. NOTE: Valley breaks are generally an indication of serious rope deterioration at strand-tostrand contact points and do not usually occur in isolation.

(h)

Outer wire wear Uniform wear of the outer wires over at least two rope lays has reduced the outer wire diameter by more than one third. NOTE: See Table D1, Appendix D.

(i)

Rope diameter The rope diameter, determined in accordance with Clause 2.4.2, has been reduced by more than 6%, due to wear, core diameter reduction, core deterioration or corrosion.

(j)

Loss of area The loss of metallic area, as determined by a non-destructive examination, exceeds 6%; unless a competent person recommends in writing that it may continue to be used, subject to a maximum of 10%.

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AS/NZS 4812:2003

(k)

Distortion Where a distortion of the rope structure, such as waviness or kinks, has occurred, the rope shall be replaced, unless a competent person (see Clause 1.3.3) has advised that it is satisfactory for continued service.

(l)

Heat damage The damage due to heat effects has resulted in pitting, distortion or any other signs of damage. NOTE: Where any part of the rope has been heated to more than about 500°C (just visible dull red heat), even momentarily, it will be embrittled and suffer noticeable loss in strength. Any indications that this has happened, such as charring, scaling or discolouration, should immediately highlight to the examiner that a competent person should give an assessment.

(m)

Combination of faults A number of faults, each of which may not exceed any of the above limitations, that may as a combined effect cause the rope to be unacceptable. NOTE: Discard is often due to combined effects, rather than effects in isolation.

3.3 GUIDE ROPES AND RUBBING ROPES

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The intent of the discard criteria below are to prevent the use of a rope with a loss of breaking force of the rope from exceeding 20%. Guide ropes and rubbing ropes have different duty conditions from those of winding ropes. For ropes that do not comply with AS 3785.6, Clause 3.2 and the manufacturer’s recommendations apply. For other forms of rope construction, the relevance of the criteria in Section 3 should be considered in conjunction with the rope manufacturer/supplier and end user. The following are the criteria for the discard of guide ropes and rubbing ropes that comply with AS 3785.6:

(a)

Guide ropes shall be replaced or other corrective action taken, where a wire in the outer layer has broken. NOTE: Corrective action may be to pull the rope up, so that any broken wires close to the suspension gland can be pulled through the gland, allowing that section of rope to be cut off.

(b)

Guide ropes shall be replaced or other corrective action taken, where, in any one plane of the rope, the width of a wear flat of a round wire is more than the width of the shaped wires immediately adjacent. NOTE: Monitoring such situations will enable guide ropes to be rotated through say 90° to distribute the wear elsewhere.

(c)

Guide ropes shall be replaced where the estimated breaking force at any point is such that the factor of safety falls below 3.5, or as specified by the applicable statutory authority. In many cases, a loss of breaking force results from wear and corrosion, and can be calculated from diameter measurements. A more convenient method is to use a loss of metallic area, as determined by non-destructive testing.

(d)

A competent person has deemed any damage or overload is seriously affecting reliability.

(e)

Where the LMA reaches 12%, a competent person shall examine the rope to determine its fitness for purpose and its loss of metallic area. The ropes shall be replaced if the loss of metallic area reaches 20%.

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AS/NZS 4812:2003

FIGURE 3 TYPICAL SKETCH OF A SHAFT LAYOUT WITH A TOWER-MOUNTED FRICTION WINDER

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AS/NZS 4812:2003

NON-DESTRUCTIVE EXAMINATION WORKSHEET Organization’s name and address: Worksheet ref: (optional)

File ref: (optional) General

Customer: Site name:

Site address:

Installation/shaft: (e.g., No 1 shaft, M&M drift)

Rope designation: (e.g., head, balance, guide)

Identification: (e.g., No 1, No A, drift)

Static or dynamic: (i.e., moving or stationary rope)

Examination method: (e.g., AS …., MDG26, WI…., etc)

Examination date: Rope details

Manufacturer:

Construction:

Diameter (mm):

Original test certificate no: (if available)

Original breaking force (kN):

Working length (m): NDT equipment details

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Equipment used: (make/model or equipment)

Serial no/s:

Equipment settings: (relevant to make of equipment used) Test speed (m/s):

Rope unit position: (e.g., brace, collar, 1 m below drum)

Tested rope length: (section of rope recovered by NDT)

Untested rope length: (section of rope not covered by NDT)

Rope datum position: (reference point on rope)

Test wire location:

Arrangement of rope construction at maximum LMA reference point: Test wire dia (mm):

Test wire serial no: (or wire measuring instrument details)

Derived rope metallic area (mm2):

Test wire % of rope metallic area:

Visual inspection equipment details Micrometer:

Serial no:

Vernier callipers:

Serial no:

Lay length rule/tape measure:

Serial no:

Monocular microscope:

Serial no: Non-destructive examination results

NDT chart interpretation: Visual inspection findings: Surface lubrication—

Surface corrosion—

Surface wear—

Rope condition with respect to discard criteria: Remarks: Testing officer: (signature)

Date:

Check by: (signature)

Date:

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AS 4991—2004

Australian Standard™ Lifting devices

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AS 4991—2004 3.2.6 Connection to the crane The method of connecting to the crane or intermediate equipment shall ensure that the forces are transmitted through the gripping device in the correct alignment. 3.3 PLATE CLAMPS AND CLAMPS 3.3.1 Design

3.3.1.1

General

Plate clamps shall withstand a load of five times WLL without failure and without releasing the load.

3.3.1.2

Gripping range

The design factor given in Clause 3.2 shall apply across the specified gripping range.

3.3.1.3

Hardness of material to be lifted

The hardness of the material to be lifted shall be considered in the design of the gripping surfaces.

3.3.1.4

Sling angles

Details of the sling angles where more than one plate clamp is used in a lifting configuration shall be considered. Accessed by Wesfarmers Industrial and Safety Ltd on 21 Nov 2017 (Document currency not guaranteed when printed)

3.3.2 Testing

3.3.2.1

General

Testing shall be in accordance with Section 12. Details of the test plates including their thickness and hardness shall be recorded on the test certificate.

3.3.2.2

Type tests

Each model of a plate clamp shall be loaded in the manner in which it is designed to perform and it shall achieve a load of five times WLL without failure and without releasing the load. The thickness of the test plate used shall be the minimum possible to achieve this load.

3.3.2.3 3.3.2.3.1

Proof testing New plate clamps

New plate clamps shall be tested using a test plate with a thickness of the mean of the gripping range.

3.3.2.3.2 Repaired plate clamps Repaired plate clamps shall be tested on a plate that is 20% to 40% of the maximum gripping range and at the maximum thickness of the range.

Use 30% where possible

NOTE: The tolerance size specified is to accommodate standard plate sizes.

3.3.2.4

Testing acceptance criteria

The clamp shall perform in the manner it is intended to perform. On completion of tests, there shall be no permanent set of the components or deleterious effect on the gripping surfaces of the clamps. 3.3.3 Markings Markings shall be in accordance with Section 13.

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AS 4991—2004 3.3.4 Information to be supplied with plate clamps Information supplied with plate clamps shall be in accordance with Section 14. Specific information regarding the following shall also be supplied: (a)

Vertical lifting for one part at a time.

(b)

Operation of the safety locking device.

(c)

Surface condition (grease, paint or coating) of the part to be handled.

(d)

Clamping ranges to be observed.

(e)

Sling angles for horizontal plate clamps.

(f)

Maximum hardness of plate that can be lifted.

3.3.5 Maintenance, inspection and repair Maintenance, inspection and repair shall be in accordance with Section 15. If the cam or pad is worn, the plate clamp shall be withdrawn from service. When repairing plate clamps, only replacement parts approved by the manufacturer shall be used. After repair, the plate clamp shall be tested in accordance with Clause 3.3.2.3.2. Accessed by Wesfarmers Industrial and Safety Ltd on 21 Nov 2017 (Document currency not guaranteed when printed)

3.3.6 Care and use Care and use shall be in accordance with Section 16. The following also applies to the care and use of plate clamps: (a)

Plate clamps shall be lifted in accordance with the manufacturer’s instruction.

(b)

An appropriate size clamp shall be selected for the intended lift(s).

(c)

Plate thickness shall be within the grip range shown on the clamp. In some cases with hardened plates or light plates (less than 20% of capacity marked on plate) and thin plates (less than 25% of the maximum clamping range) the clamping force will be reduced. In these cases, before lifting, it shall be confirmed that the clamp has a positive grip.

(d)

The load should be taken up slowly. Jerking the load shall be avoided.

(e)

The surfaces of the cam and pad shall be protected from weld spatters or other damaging contaminants.

(f)

The surface of the load shall be clean and free from scale.

(g)

Plate clamps should not be used to support suspended plates in power or break presses during operation.

3.4 GIRDER CLAMPS 3.4.1 Design Girder clamps are designed for vertical suspension of loads unless otherwise noted. Girder clamps shall withstand a load of five times the WLL before the load is released. This is a Type Test not a 3.4.2 Testing and verification requirements Proof Load 3.4.2.1 General Testing and verification shall be in accordance with Section 12.

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AS 4991—2004 3.4.2.2 Proof testing 3.4.2.2.1

Conditions

The test shall be conducted by applying a static force in a manner that replicates its intended use.

3.4.2.2.2

Procedure

Clamps shall be tested on a beam section within its specified range. NOTE: This enables the test load to be achieved.

Details of the test beam shall be recorded on the test certificate.

3.4.2.2.3

Testing acceptance criteria

The clamp shall perform in the manner in which it is intended to perform. On completion of tests there shall be no permanent set of the components or deleterious effect on the gripping faces of the clamps.

3.4.2.3 Type tests 3.4.2.3.1

Conditions

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Each model of a girder clamp shall be loaded by applying a static force in a manner that replicates its intended use.

3.4.2.3.2

Procedure

Clamps shall be tested on a beam section within its specified range. NOTE: This enables the required load of the specified clamps to be obtained.

3.4.2.3.3

Testing acceptance criteria

The clamp shall sustain a load of five times WLL without failure and without releasing the load. 3.4.3 Maintenance, inspection and repairs Maintenance, inspection and repair shall be in accordance with Section 15. Particular attention shall be paid to worn threads. 3.4.4 Care and use Care and use shall be in accordance with Section 16. Lifting shall be in accordance with the manufacturer’s instructions. The girder clamp used shall have an appropriately specified range for the flange width of the beam being lifted. The clamp shall be securely fitted to the beam and the centre-line of the lifting point shall be aligned to the centre web of the beam. 3.5 TONGS Tongs shall be suitably matched, in respect of size and shape, to the loads to be transported. When designing tongs to be used as load-carrying means, the following additional data shall be specified: (a)

Numerical values for the range of opening of the tongs and for the vertical closing lift (related to the centre point of the tongs suspension).

(b)

Load on the tongs and tare mass of the tongs.

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AS 4991—2004

SEC TION

B I NS

4.1 DESIGN 4.1.1 General General design requirements for bins shall be in accordance with Section 2. NOTE: For illustrated examples of bins, see Appendix B.

4.1.2 Volume Where a bin is designed for a particular application, the volume shall be limited to prevent overloading when filled to capacity. 4.1.3 Bin discharge

4.1.3.1

Discharge mechanism

Discharge mechanisms for the bin may include tipping lugs, self-disengaging arms or discharge slides. Any self-disengaging mechanisms shall be arranged so as to prevent inadvertent disengagement. Accessed by Wesfarmers Industrial and Safety Ltd on 21 Nov 2017 (Document currency not guaranteed when printed)

4.1.3.2

Discharge slides

Discharge slides may be fitted to enable control of the rate of material discharge. Discharge slides shall incorporate devices or features that prevent unintended opening. NOTE: This can be achieved by a locking device at the opening mechanism.

Discharge slides shall incorporate devices or features that prevent unintended tilting or swivelling at each loading state. NOTE: This can be achieved, for example, by— (a)

a manually activated locking device;

(b)

the tilting mechanism being irreversible; or

(c)

an additional braking device.

4.1.4 Baffling Where there is a possibility of a sudden change in the stability of the load during transport or lifting of fluids, baffling should be included. 4.2 SET DOWN Bins shall be designed so that they can be set down in a stable manner in each loading state. 4.3 TESTING AND VERIFICATION Testing and verification of bins shall be in accordance with Section 12. 4.4 MARKING Bins shall be marked with the following information: (a)

Gross load or WLL or rated capacity.

(b)

Tare mass.

(c)

Identification number.

(d)

Material to be lifted (if applicable).

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AS 4991—2004 4.5 INFORMATION TO BE SUPPLIED WITH BINS The information to be supplied with bins shall be in accordance with Section 14. 4.6 MAINTENANCE, INSPECTION AND REPAIR Maintenance, inspection and repair of bins shall be in accordance with Section 15. 4.7 CARE AND USE

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Care and use of bins shall be in accordance with Section 16.

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AS 4991—2004 ‘Operating range’ is the range of working pressure specified by the manufacturer for operation. ‘Non-operating range’ is outside the working pressure. NOTE: The operating range may be in green and the non-operating range be in red, but other methods of indication are acceptable.

5.3.3 Self-priming vacuum lifters Self-priming vacuum lifters shall be equipped with a vacuum indicator to warn the operator of leakage. 5.4 VACUUM LOSS CONTROL AND MONITORING

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Where a system is provided to control and monitor vacuum losses, it shall be as follows: (a)

In the case of vacuum lifters with a vacuum pump, a vacuum reservoir with a non- return valve between the vacuum reservoir and the pump located as close as possible to the vacuum reservoir shall be provided.

(b)

In the case of vacuum lifters with a venturi-system, a positive pressure reservoir or a vacuum reservoir with a non-return valve between the vacuum reservoir and the venturisystem located as close as possible to the vacuum reservoir shall be provided.

(c)

In the case of turbine (side channel blower) vacuum lifters, a supporting battery or a flywheel mass shall be provided. This does not apply to vacuum tube lifters.

(d)

In the case of self-priming vacuum lifters, a reservoir equal to a minimum of 50% of the total piston volume shall be provided. The ratio of the surface area of the suction plate to the surface area of the piston shall be equal to or greater than 2. An excess vacuum thus exists when the rated load is reached and this is regarded as a vacuum reserve.

A device that gives an optical or acoustic indication, or both, shall be provided to indicate the danger level when the control device cannot balance the loss in vacuum. This indication shall be automatic and clearly perceptible to the operator. NOTE: Vacuum losses can occur due to leaks, or in the case of non-self-priming vacuum lifters, due to a power failure.

5.5 DESIGN FOR USE IN PROXIMITY TO PEOPLE For vacuum lifters that are intended for use in areas where people may be present and subject to risks associated with inadvertent release of the load, the requirements of Clause 5.3 shall apply. The following additional requirements shall also be fulfilled. (a)

Operation The operating elements with which the load can be released shall be secured against erroneous operation. This does not apply to vacuum tube lifters. NOTE: This can be achieved by two-action control.

(b)

Tilt angle If the vacuum lifter is intended to lift the load horizontally, it shall tolerate a tilt of up to 6° from the horizontal.

5.6 TESTING Testing shall be in accordance with Section 12, except that— (a)

a proof load shall take place which demonstrates that the vacuum lifter can perform its intended function; and

(b)

in addition, the supporting structure excluding the lifting tube, shall achieve a static proof load of two times the WLL.

NOTE: This proof load does not require the lifting of any load by means of the vacuum.

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AS 4991—2004 5.7 VACUUM LIFTER MARKINGS Vacuum lifters shall be marked in accordance with Section 13. 5.8 INFORMATION TO BE SUPPLIED WITH VACUUM LIFTERS The information to be supplied with vacuum lifters shall be in accordance with Section 14. 5.9 MAINTENANCE, INSPECTION AND REPAIR Maintenance, inspection and repair of vacuum lifters shall be in accordance with Section 15. 5.10 CARE AND USE

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Care and use of vacuum lifters shall be in accordance with Section 16.

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AS 4991—2004 6.6 ELECTRO-PERMANENT LIFTING MAGNETS 6.6.1 Design factor Electro-permanent lifting magnets shall provide a tear-off force of at least 3 times the rated capacity, for the least favourable loading configuration, as specified by the manufacturer. 6.6.2 Magnetic state indicator An indicator shall be provided to show when the magnet(s) is magnetized. For magnets with variable power control, the indicator shall distinguish between full and partial magnetism. 6.7 ASSOCIATED STANDARDS Magnet systems shall be designed in accordance with the following: AS 2676.1, AS 2676.2, AS 3011.2, AS 3947.1, AS 4044, AS 60529, AS/NZS 3000, AS/NZS 3100, AS/NZS 3108, AS/NZS 4251.1, AS/NZS 4251.2, AS/NZS 4252.1. 6.8 MARKING Magnet lifters shall be marked in accordance with Section 13.

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6.9 MAGNET TESTING Testing of magnets and associated power supplies shall be carried out by a competent person experienced in magnet systems. The magnet or magnet system shall be tested in a manner similar to its intended use in service, at a rate that minimizes dynamic loads, and shall sustain a minimum tear-off force of twice the rated capacity for the type of load. The type and condition of the items lifted shall be recorded on the testing certificate. 6.10 INFORMATION TO BE SUPPLIED The information to be supplied with magnet lifters shall be in accordance with Section 14. 6.11 MAINTENANCE, INSPECTION AND REPAIR Maintenance, inspection and repair of magnet lifters shall be in accordance with Section 15. 6.12 CARE AND USE Care and use of magnet lifters shall be in accordance with Section 16.

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AS 4991—2004

SEC TION

C -HOOKS

7.1 GENERAL General design requirements for C-hooks shall be in accordance with Section 2. NOTE: For illustrated examples of C-hooks, see Appendix B

7.2 DESIGN 7.2.1 Load stability C-hooks shall support the load in a stable manner on the lower arm during lifting and transport operations, as specified by the manufacturer’s instructions. 7.2.2 Load security Means shall be provided to prevent the load from sliding on the lower arm, or the load, or to prevent part of the load from falling.

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NOTE: This can be achieved, for example, by— (a)

the C-hook tilting backwards;

(b)

a system to close the C-hook opening;

(c)

a system to secure the load by clamping appropriate to the mass of the load;

(d)

an end stop at the end of the lower arm;

(e)

the C-hook being maintained in horizontal position provided the friction coefficient between load and lower arm(s) is sufficient to prevent the load from sliding; or

(f)

the lower arm being shaped appropriately to suit the lifted load.

7.2.3 Protection Where required, protection against damage to the load should be provided on the C-hook. 7.2.4 Storage When not required for use it shall be possible to set down the C-hook so that it is stable during storage. It may be necessary to place the C-hook in a stand or incorporate feet in the design. 7.3 TESTING AND VERIFICATION Testing and verification of C-hooks shall be in accordance with Section 12. 7.4 MARKING C-hooks shall be marked in accordance with Section 13. 7.5 INFORMATION TO BE SUPPLIED The information to be supplied with C-hooks shall be in accordance with Section 14. 7.6 MAINTENANCE, INSPECTION AND REPAIR Maintenance, inspection and repair of C-hooks shall be in accordance with Section 15. 7.7 CARE AND USE When using C-hooks, the following shall be observed: (a)

Checking the load centre of gravity to prevent the load from sliding.

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AS 4991—2004

SEC TION

LIFT ING

FOR KS

8.1 GENERAL Tynes attached to a forklift or telescopic handler are not covered by this Section. 8.2 DESIGN 8.2.1 General General design requirements for lifting forks shall be in accordance with Section 2. 8.2.2 Load stability Lifting forks shall be designed so that the load remains stable on the tynes during lifting and transport operations, as specified by the manufacturer’s instructions. 8.2.3 Load security Means shall be provided to prevent the load from sliding on the tynes, or the load or part of the load from falling:

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NOTE: This can be achieved, for example, by— (a)

lifting the lifting fork backwards in loaded position;

(b)

maintaining the lifting fork in the horizontal position provided the friction coefficient between load and lower arms is sufficient to prevent the load from sliding; or.

(c)

safety chains, straps, wrapping or similar.

8.2.4 Storage When not required for use, it shall be possible to set down the lifting fork so that it is stable during storage. 8.3 TESTING AND VERIFICATION Testing and verification of lifting forks shall be in accordance with Section 12. 8.4 MARKING Lifting forks shall be marked in accordance with Section 13. 8.5 INFORMATION TO BE SUPPLIED The information to be supplied with lifting forks shall be in accordance with Section 14. 8.6 MAINTENANCE, INSPECTION AND REPAIR Maintenance, inspection and repair of lifting forks shall be in accordance with Section 15. 8.7 CARE AND USE When using lifting forks, the following shall be observed: (a)

Taking care to prevent the load from sliding on the tynes, or the load or part of the load from falling. NOTE: This can be achieved, for example by— (a)

safety chains, straps, wrapping or similar;

(b)

a system to keep the load in its place appropriate to the mass; or

(c)

balancing the load on the tynes so that the loaded fork does not tilt forward during operation.

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AS 4991—2004

SEC TION

LIFT ING

BEAMS

9.1 GENERAL General design requirements for lifting beams shall be in accordance with Section 2. NOTE: For illustrated examples of lifting beams, see Appendix B.

There are three types of lifting beams: (a)

Lifting beam—a lifting beam that is placed in bending by the applied load(s).

(b)

Spreader beam or bar—a spreader beam or bar that is placed in axial compression by the applied load.

(c)

Combination beam—a beam that combines both bending and axial compression loads in the one beam.

9.2 DESIGN 9.2.1 Stability

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Lifting beams shall be designed so that the load remains stable during lifting and transport operations, as specified by the manufacturer’s instructions. Means shall be provided to maintain the lifting beam stability and to prevent any dangerous movement and damage to the suspended elements of the lifting beam e.g., handles or guiding devices, to prevent uncontrolled movement during operation. 9.2.2 Adjustable beams/attachments Adjustable lifting beams or beams having adjustable attachments shall have a positive means to secure the adjustable component in position. Such means shall be identifiable as being locked or unlocked. 9.2.3 Beams with mechanical devices Moving parts of the structure shall have devices to hold them in position when loaded. If these devices operate on a friction basis, the factor on the holding load shall be at least 2. If free movement of the beam presents a hazard, i.e., swivelling, lifting beams fitted with a rotation or tilting mechanism shall be equipped with a device to stop movement and to immobilize the load in its intended position. When the spacing between moving parts of the beam is controlled by a power source, protection devices shall be provided to avoid crushing and shearing hazards to personnel, e.g., guarding. 9.3 TESTING AND VERIFICATION Testing and verification of lifting beams shall be in accordance with Section 12. 9.4 MARKING Lifting beams shall be marked in accordance with Section 13. 9.5 INFORMATION TO BE SUPPLIED The information to be supplied with lifting beams shall be in accordance with Section 14. 9.6 MAINTENANCE, INSPECTION AND REPAIR Maintenance, inspection and repair of lifting beams shall be in accordance with Section 15.

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AS 4991—2004

SEC TION

1 2

T E S TIN G

AND

V E RIF IC A TIO N

12.1 GENERAL The manufacturer’s testing shall verify that the equipment performs in accordance with the original design requirements. 12.2 PROOF LOADING 12.2.1 General application lifting devices Except as otherwise determined by Clause 12.3, lifting devices shall be proof-loaded in accordance with the following: (a) (b) (c)

Up to 10 t ................................................... 2 × working load limit or rated capacity.

10–160 t ................................... (1.04 × working load limit or rated capacity) + 9.6 t.

Above 160 t ............................................. 1.1 × working load limit or rated capacity.

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Proof-loading shall be applied in a manner similar to its intended use in service, but shall be applied at a rate that minimizes dynamic loads. The proof-load shall be applied subsequent to any heat treatment required in the manufacture of the item of lifting equipment.

Where a testing machine is used, it shall be calibrated in accordance with AS 2193 and shall be capable of meeting Grade C requirements. Where weights are used, a tolerance of ±5% of the known mass of the test weight shall apply. The test laboratory shall have procedures in place that comply with AS/ISO/IEC 17025. 12.2.2 Specific application lifting devices Where the lifting device is designed for a specific application, the lifting device shall be proofloaded in accordance with the relevant Part of AS 1418. 12.2.3 Acceptance criteria A method to measure included permanent deformation shall be applied. This method may consist of marking the item of lifting equipment in two locations on the body and measuring the distance between the marks. After applying the proof- load for a time of not less than 1 min, the load shall be removed from the lifting devices, and the distance between the marks shall be remeasured and the dimensions compared to the original. Any permanent set in the dimension shall not exceed 0.25% of the original dimension. The lifting device shall receive a further visual or non-destructive testing examination by a competent person for evidence of flaws or defects following the test. 12.3 ALTERNATIVE VERIFICATION Where the designer or competent person deems that a proof load is not required, a substitute testing regime shall be implemented. Such a testing regime shall include either of the following, as appropriate: (a)

Reduced proof-loads as prescribed by alternative standards where these loads are greater or equal to the working load limit/rated capacity.

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AS 4991—2004 A non-load-applying test regime involving all of the following: (i)

Third-party design analysis.

(ii)

Material identification and non-destructive examination of welds.

(iii)

Castings and other appropriate non-destructive examination.

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(b)

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AS 4991—2004

SEC TION

1 3

E Q U I P M EN T

M A R KING S

13.1 MINIMUM MARKING Subject to Clause 13.2.2, lifting devices shall be clearly marked with the following information, as appropriate: (a)

Identification of manufacturer (or authorized representative or importer).

(b)

Model, where applicable.

(c)

Identification number.

(d)

Tare mass of equipment when it exceeds 50 kg.

(e)

Working load limit/rated capacity in kilograms where less than 1 t, in tonnes where greater than 1 t. When the equipment can be used in several configurations, WLL/rated capacities for each configuration shall be indicated.

(f)

The group classification, as defined in AS 1418.1, when greater than Class C3.

Tare mass and working load limit/rated capacity shall be marked in the same unit of measurement.

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13.2 ADDITIONAL MARKING 13.2.1 General In addition to the data in Clause 13.1, the following shall be stated, where applicable: (a)

On equipment for bulk materials, the volumetric capacity (in cubic metres or litres).

(b)

On equipment that holds the load using clamping forces, the permissible gripping range of the material to be handled.

(c)

On self-priming vacuum lifters, the maximum load.

(d)

On electrically powered equipment, the allowed supply voltages.

(e)

On lifting beams, the maximum permissible included sling angle applicable to the design of the spreader or combination beam.

13.2.2 Specific applications The following specific applications shall apply: (a)

Where equipment markings can be destroyed by normal use of the lifting device, e.g., ladles for molten material, lifting frames for use within furnaces or pickling baths, the information listed in Clause 13.1 need not be marked on the device. Instead, the information shall be safely documented and a working copy shall always be kept available for operators at or near the place of use.

(b)

Clause 13.1, Item (f) does not apply for load lifting magnets, provided the lifting capacity can be taken from documents at the place of use.

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AS 4991—2004

SEC TION

1 5

M AINT E NA N CE , A N D R E P AIR

INS P E C TI ON

15.1 INSPECTIONS 15.1.1 General Where the correct inspection frequency is unknown, guidance may be obtained from AS 2550.1. 15.1.2 In-service Prior to each use or shift, lifting devices shall be visually inspected to ensure the device is free of any significant damage or wear and markings are legible. If any defects are detected, the lifting device shall immediately be withdrawn from service. 15.1.3 Periodic

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Lifting devices shall be inspected by a competent person at intervals specified by the manufacturer or, in its absence, at intervals specified by a competent person, taking due consideration of the working environment and the manner in which the lifting device is used. Inspections shall be undertaken in accordance with the following: (a)

Inspections shall be undertaken in an adequately lit location.

(b)

The lifting device shall be cleaned before it is inspected.

(c)

Any worn components shall be measured to determine the degree of wear, which shall not exceed that allowed. Wear may be tolerated until the thickness of any worn section has been reduced by 10% or other specified value of the nominal section in any plane

(d)

All components shall be inspected for any signs of wear at their load-bearing or highly stressed points. Signs of wear include nicks, cracks, gouging, stretching or distortion.

An inspection record shall be maintained for each lifting device. Regulatory requirements may require results to be entered on an inspection record. NOTE: The application of a magnetic particle inspection method may assist in the identification of faults otherwise not visible using the unaided eye.

15.1.4 Defects requiring withdrawal from service If any of the following defects are visible, the lifting device shall be withdrawn from service and referred to a competent person: (a)

Markings that have become detached or illegible. In such cases the lifting device may be returned to service after being assessed by a competent person that it— (i)

is in good condition; and

(ii)

has been remarked following verification of its identity and capacity.

Recording shall be carried out in accordance with this Standard. (b)

Cuts, nicks, gouges, cracks, excessive corrosion, heat damage, bent or distorted components or any other defects. NOTE: Shallow and rounded indentations in areas of low tensile stress may not affect the structural integrity, but deep nicks in high-tension areas and sharp transverse nicks could affect the structural integrity.

(c)

Signs of overloading, such as any visible deformation of components.

Lifting devices having any defects shall be clearly marked to indicate rejection, and the lifting device shall be withdrawn from service.

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AS 4991—2004 15.2 REPAIR Any replacement component or part of the lifting device shall be in accordance with this Standard or the manufacturer’s specifications for that component or part. Components that are cracked, visibly distorted or twisted, severely corroded or have deposits that cannot be removed shall be discarded. Where appropriate, minor damage such as nicks and gouges may be removed by careful grinding and filing. Following repair, the surface should blend smoothly into the adjacent material without abrupt change of section. The complete removal of the damage should not reduce the thickness of the section at a point by more than 10% of the nominal dimension in any plane. Where it is anticipated the repair will remove material to a depth greater than 10% of the original material thickness, the proposed repair shall be referred to the original manufacturer or a competent person for assessment prior to the repair proceeding. After structural repair or subsequent work to load-bearing components, either of the following shall be undertaken: Application of a proof load in accordance with Section 12.

(b)

A repair procedure in accordance with Appendix C.

Accessed by Wesfarmers Industrial and Safety Ltd on 21 Nov 2017 (Document currency not guaranteed when printed)

(a)

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AS/NZS 5532:2013

Australian/New Zealand Standard Manufacturing requirements for singlepoint anchor device used for harnessbased work at height

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AS/NZS 5532:2013

7 INSTRUCTIONS FOR USE AND MARKING 7.1 Instructions for general use Anchor devices shall be supplied with clear instructions explaining installation and general use, including reference to the following: (a)

Instructions containing appropriate detail, supplemented by sketches if necessary, to enable the purchaser to install and use the device or system correctly. A statement that the device is for personnel use and not for materials use.

(b)

A statement of any limitations of the product, including the following: (i)

Restrictions of use due to design features such as material properties and temperature performance.

(ii)

Installed anchor life expectancy will be dependent on the material properties of the anchor device, the life expectancy of the structure to which it is connected to and the life expectancy of the fixing methodology.

(iii) Issues with associated hardware, such as bolts, fixings to concrete and the like. (iv)

The need for professional guidance on the design of multiple anchor systems.

(v)

Any restrictions on connection equipment.

(vi)

A warning to consider possible corrosion issues between the anchor device, its fixings and the structure to which it is attached.

(vii) Restrictions in use in areas with possible corrosive conditions. (viii) A warning against making any alterations or additions to the product without the prior, written consent of the manufacturer. (c)

Advice that a record be kept and made available to users for each system, containing at least the following particulars: (i)

Identification mark(s).

(ii)

Manufacturer s or supplier s name and address, and the manufacturer s serial number, if any.

(iii) Suitability for use with other components within harness based work at height systems. (iv)

Date of purchase.

(v)

Date first put into service.

(vi)

Date the next examination/service is due.

(vii) A space for comments. (d)

Instructions that, where practical, the anchor device or system be located above the position of the user.

(e)

Instructions that, immediately before use, the user needs to (i)

make a visual inspection of the anchor device or system to ensure that it is in a serviceable condition;

(ii)

review the recommendations for use with other components within a system, as advised on the record card for the system or component, are complied with;

(iii) check the compatibility with attachment hardware;

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AS/NZS 5532:2013

(iv)

check that the anchor rating is suitable; and

(v)

have the device or system removed from service immediately if the system or device has been used to arrest a fall, or should any doubt arise as to its safe condition, until such time that it has been inspected and, if appropriate, tested by a competent person.

(f)

An instruction that the system or device be examined at a frequency deemed necessary by the manufacturer, and an instruction that the device be inspected (at least once every 12 months) by a competent person.

(g)

A warning that compatibility between the anchor and any connector used with it is critical (e.g. Figure 7).

(h)

The attachment of a label or marking to each anchor identifying it for personnel attachment only.

7.2 Marking Each assembled product/detachable component of a system shall be clearly, indelibly and permanently marked, by any suitable method not having a harmful effect on the materials, with the following identification marks: (a)

The manufacturer or supplier s name, trade mark or other means of identification.

(b)

The manufacturer s batch number or serial number of the component.

(c)

The product rating, in kN, or capacity (e.g. single person/limited freefall).

The characters in the identification mark shall be readable and discernible after installation. Each anchor shall have an attached label or marking to identify it for personnel attachment only. Product supplied as a group of components to be assembled shall be packaged as a single unit package and marked as above. 7.3 System design and installation information System design and installation information shall be supplied with anchor devices. Include the following information, as a minimum: (a)

Where a layout of multiple anchor points is required, ensure the anchor positions and layout are designed by a competent person who also ensures that adequate fall clearances have been taken into account.

(b)

Where anchor devices are to be installed in an existing building, the types of structure should be checked to ascertain the nature and thickness of the structural materials, and appropriate fixings should be selected. Ensure that decorative coatings are removed to ensure the correct evaluation of the substrate. The installer needs to follow the manufacturer s instructions in addition to those of the designer of the installed system.

(c)

The design and method of installation for fixings in steelwork or timber, or the need for verification by a suitably qualified engineer that the substrate is capable of sustaining the rated loading of the anchor.

(d)

Where the fixing is in a substrate other than those specified in the manufacturer s instructions for use, the installer needs to refer to the system designer who may also require verification of suitability by carrying out a test in a sample of the material. The sample is required to meet the requirements of the relevant test specified in Clause 5 of the Standard (AS/NZS 5532).

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AS/NZS 5532:2013

(e)

Take care to assess the suitability of a portable anchor device and any associated fixings for the application in which it is to be used. Follow the manufacturer s instructions.

(f)

The need to ensure that every friction or glued-in anchorage requires the anchor rating to be proof-loaded to 50% of rated capacity in accordance with the manufacturer s instructions after installation and prior to initial use. Apply the proof-load as an axial pull out force.

(g)

A competent person must visually inspect top fix anchors incorporating gluing onto roof sheeting to check that the edges of the gluing have bonded (i.e. have no gaps).

(h)

The system installer needs to review the minimum clearance required or necessary to arrest the fall of a falling worker. This should not exceed the distance available on-site.

(i)

The system installer needs to make the system and user information available to the user before the user accesses the system.

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AS EN 12079.3—2010

Australian Standard® Offshore containers and associated lifting sets Part 3: Periodic inspection, examination and testing (EN 12079-3:2006, MOD)

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Offshore containers and associated lifting sets

AS EN 12079.3—2010

Part 3: Periodic inspection, examination and testing (EN 12079-3:2006, MOD) 1

Scope

This part of EN 12079 specifies requirements for the periodic inspection, examination and testing of offshore freight and service containers, built in accordance with EN 12079-1, with maximum gross mass not exceeding 25000 kg and their associated lifting sets, intended for repeated use to, from and between offshore installations and ships. Inspection requirements following damage and repair of offshore containers are also included. Other parts of the standard are: EN 12079-1, Offshore containers and associated lifting sets - Part 1: Offshore container – Design, manufacture and marking EN 12079-2, Offshore containers and associated lifting sets - Part 2: Lifting sets – Design, manufacture and marking Guidance as to the knowledge and experience required by those responsible for carrying out periodic inspection and testing is given in Annex A 'Recommended knowledge and experience of staff responsible for inspection of offshore containers'. Guidance on pre-trip inspections is given in Annex B ' Recommended knowledge and experience of staff responsible for inspection of lifting sets intended for use with offshore containers'.

Normative references

The following referenced documents are indispensable for the application of this European Standard. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 12079-1:2006, Offshore containers and associated lifting sets — Part 1: Offshore containers — Design, manufacture and marking EN 12079-2:2006, Offshore containers and associated lifting sets — Part 2: Lifting sets — Design, manufacture and marking EN 473, Non-destructive testing - Qualification and certification of NDT personnel - General principles EN 571-1, Non-destructive testing - Penetrant testing - General principles EN 818-4:1996, Short link chain for lifting purposes - Safety - Part 4:Chain slings - Grade 8 EN 818-6, Short link chain for lifting purposes - Safety - Part 6:Chain slings - Specification for information for use and maintenance to be provided by the manufacturer EN 970, Non-destructive examination of fusion welds - Visual examination EN 1289, Non-destructive examination of welds - Penetrant testing of welds - Acceptance levels EN 1290, Non-destructive examination of welds - Magnetic particle examination of welds EN 1291, Non-destructive testing of welds - Magnetic particle testing of welds - Acceptance levels EN 1435, Non-destructive examination of welds - Radiographic examination of welded joints Bullivants | Page 571 of 692

AS EN 12079.3—2010 NOTE 2 R, T and P are, by definition, in units of mass, kilograms (kg). Where design requirements are based on the gravitational forces derived from these values, those forces are indicated thus: Rg, Tg and Pg the units of which are in newtons or multiples thereof.

Container inspection plate

5.1 General Containers shall be fitted with a plate carrying the information specified in 5.2. The plate shall be made of corrosion resistant material securely attached externally in a manner designed to avoid unauthorized or accidental removal. The plates shall be fitted to a door, or, on containers with no doors, in a prominent position. Aluminium rivets have been found to be unsuitable as a fixing method in the offshore environment and shall not be used. The information on the plate shall be in the English language (see Note). The text shall be permanently and legibly marked on the plates in characters not less than 4 mm high. NOTE Provision for an additional language may be made.

5.2 Contents of inspection plate The plate shall be headed “OFFSHORE CONTAINER INSPECTION PLATE - EN 12079-3: 2006" The plate shall contain the following information: a)

owner’s container number;

owner’s name;

date of last inspection.

The date of last inspection shall be the date on which the most recent inspection was carried out to the satisfaction of the competent person. To avoid confusion, the plate shall not carry the date of the next inspection. Provision shall be made on the plate to facilitate permanent marking to record a minimum of nine inspections. NOTE 1 For marking of the inspection plate see Clause 10. NOTE 2 A recommended format for the plate is shown in Figure 1.

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AS EN 12079.3—2010 OFFSHORE CONTAINER INSPECTION DATA Container no.: Owner: Inspections: 1 2 3 4

10 NOTE The information required for the inspection plate may be combined with the Offshore Container Data Plate (see EN 12079 - 1).

Figure 1 — Example of Inspection Plate

Schedule of periodic inspection/ examination and test — containers

Containers and lifting sets shall be periodically inspected, examined and if necessary tested in accordance with the schedule listed in Table 1, by an inspection body meeting the requirements of EN ISO/IEC 17020. NOTE 1 Guidance as to the recommended knowledge and experience of staff responsible for inspections for the purposes of EN ISO/IEC 17020 is given in Annex A.

When the schedule includes a lifting test, the non-destructive examination and visual inspection shall both be carried out after the lifting test. NOTE 2 The inspection body may require other or additional inspections, examinations and or tests.

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AS EN 12079.3—2010 The container shall be carefully lifted in such a way that no significant acceleration forces occur. It shall be held for 5 minutes before measurements are taken. No deflections during testing shall be greater than 1/300 of the span of the member. The offshore container shall show no permanent deformation or other damage after testing.

7.2

Test equipment and calibration

The force shall be applied using calibrated weights and lifting the container by a lifting appliance or by means of a suitable test rig (see EN 12079-1:2006, 7.3.2).

Non-destructive examination of welds

8.1

General

The NDE of welds on pad eyes and adjoining structures shall be carried out in accordance with the schedule of examination and tests specified in Table 1. NOTE

8.2

Alternative or additional examination may be required by the inspection body.

Non-destructive examination (NDE) methods

NDE methods, see Table 2, shall be chosen with due regard to the conditions influencing the sensitivity of the methods. Structural welds shall be examined as stipulated in columns I to IV of Table 7 in EN 12079-1 with the method in columns III or IV being employed in the event that such is relevant. Table 2 — Standards relevant to NDE methods Visual

Magnetic particle

Dye Penetrant

Ultrasonic

Radiography

EN 970

EN 1290

EN 571-1

EN 1714

EN 1435

Table 3 - NDE acceptance criteria Visual

Magnetic Particle

Dye Penetrant

EN ISO 5817 a

EN 1291

EN 1289

EN 1712

EN 12517-1

Level B

Level 1

Level 2

Level 1

8.3

Ultrasonic

Radiography

for aluminium EN 30042

Non-Destructive Examination (NDE) Operators

NDE Operators shall be qualified, in accordance with EN 473, to a minimum of level 2. NDE operators shall undertake non-destructive examination in accordance with Table 2 and issue reports describing quality, containing the following information as a minimum: 

number of repairs carried out to meet the specified acceptance standard;



NDE methods and procedures used;



NDE-parameters necessary for a proper assessment;



confirmation of acceptance or rejection.

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AS EN 12079.3—2010 Table 4 — Pre-trip inspection — Required checks a)

inspection plate(s) to ensure that inspection dates are current;

container for obvious signs of excessive corrosion or damage;

lifting set for obvious signs of damage;

lifting set to establish that all parts are present, correct, properly connected and secure;

container roof, forklift pockets (and frames on open frame containers) for loose items;

container door(s) are closed and the locking mechanism secured.

13 Record keeping The owner shall retain the current certification for each container, record substantial repairs, modifications or changes in identification etc., and maintain adequate records to ensure traceability.

14 Damage and repair procedures The owner shall ensure that: 

containers are maintained in accordance with this standard;



if a container is damaged such that it does not comply with this standard, it is not used until it is repaired and inspected by an inspection body;



repairs are carried out in accordance with the requirements for design and manufacture of containers set out in EN 12079-1;



repair facilities used are able to ensure the quality of the procedures and facilities by a quality assurance system at least in accordance with EN ISO 9001 or EN ISO 3834-2;



following repair, the container is inspected and where relevant tested by the inspection body in accordance with Table 1. To this end, the owner shall provide the inspection body with full details of the repairs that have been carried out;



following modification, the container is submitted for re-certification.

NOTE 1 If the user or any of his agents detects any structural damage or corrosion which may affect the load bearing integrity of the container, it is strongly recommended that they advise the owner as soon as practicable. NOTE 2 Where a need for repair is identified, it will be necessary to make adequate arrangements for the safe transportation of the damaged container, to the location specified by the owner.

15 Schedule of inspection/examination and test — Lifting sets 15.1 Lifting sets shall be periodically inspected, examined and tested, by an inspection body in accordance with the schedule detailed in Table 5. 15.2 When the schedule requires a load test, any non-destructive examination and visual inspection shall both be carried out after the load test. NOTE 1

The inspection body may require other or additional inspections, examinations and or tests.

NOTE 2 Guidance as to the recommended knowledge and experience of staff responsible for inspections is given in Annex B.

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AS EN 12079.3—2010 Table 5 — Schedule of periodic inspection, examination and testing of lifting sets Time or interval

Applicable to

Inspection/examination/test Load test

Initial certification

Interval not exceeding 12 months Interval not exceeding 48 months

After substantial repair or alteration a

Complete lifting set

Nondestructive examination

Visual inspection

Suffix marked on sling tag

As required by EN 12079-2

Complete lifting set

N/A

Yes

Sling components and joining links excluding legs

Either load test or NDE

Yes

T or VNa

Chain sling legs

Either load test or NDE

Yes

T or VNa

Shackles

N/A

Yes

N/A

Complete lifting set

Yes

Dependent upon whether tested or examined

15.3 Load testing of chain sling legs A test load equal to 2.5 x WLL of a single leg rated in accordance with EN 818-4:1996 (Table 3) +/2 %, shall be applied to each leg without shock. The load shall be applied for a minimum of 5 minutes before measurements are taken.

15.4 Non-destructive examination of sling components except wire rope legs Magnetic particle examination shall be undertaken as specified in Clause 8.

15.5 Visual inspection of the lifting set 15.5.1 General The inspection shall be carried out with normally corrected vision, in a situation providing sufficient lighting and other facilities necessary to allow it to be carried out safely and effectively. 15.5.2 Chain and wire rope slings and components. Inspection of chain and wire rope slings and components shall be carried out in accordance with EN 818-6 and 13414-2 as applicable. 15.5.3

Shackles

Shackles shall be visually inspected.

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AS EN 12079.3—2010 15.6 Marking of the lifting set identification tag On satisfactory completion of inspection/examination/test, as applicable, the sling identification tag shall be permanently marked, in accordance with Table 5 as follows: 

the date YY-MM-DD of the inspection/examination/test as applicable, together with the unique identification mark of the inspection body together with either;



suffix T: indicating load test; non-destructive examination, and visual inspection; or



suffix V: indicating visual inspection only; or



suffix VN: indicating NDE and visual inspection.

15.7 Inspection report When, in the opinion of the inspector, a lifting set is suitable for service, a report shall be issued to the owner, containing the following information (as a minimum): 

sling and shackle identification numbers;



owner’s name;



report number;



statement that the lifting equipment described was thoroughly inspected, examined and tested, is safe to operate and that the particulars are correct;



details of any NDE carried out;



confirmation that the sling identification tag was marked; date of inspection (date of signature or report also to be shown if different from date of inspection);



name of organization, name of the person and authentication by the person carrying out the inspection/ examination or test either by signature or other secure means.

NOTE

Details of the inspection of the container may also be given on the Inspection Report for the lifting set.

15.8 Record keeping The owner shall retain the current certification for each lifting set and maintain adequate records to ensure traceability.

15.9 Damage and repair procedures The owner shall ensure that: 

lifting set is maintained in accordance with this standard;



if the lifting set is damaged it shall not be used until it is repaired or replaced, and inspected by an inspection body;



lifting set repairs shall be carried out in accordance with the requirements of EN 12079-2;

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AS EN 12079.3—2010 

repair facilities used are able to ensure the quality of the procedures and facilities by a quality assurance system at least in accordance with EN ISO 9001;



following repair, the lifting set is inspected and where relevant tested, by an inspection body in accordance with Table 5. The repairer shall provide the inspection body with full details of the repairs that have been carried out. Any modifications will require re-certification of the lifting set by an inspection body.

NOTE If the user or any of his agents detects any damage or corrosion which may affect the integrity of the lifting set, it is strongly recommended that they advise the owner as soon as practicable.

16 Inspection of attachment of lifting set to an offshore container 16.1 Attachment The attachment of the lifting set to the container, shall be inspected by a competent person, to ensure that: 

minimum WLL of the lifting set attached to an offshore container is as specified in EN 12079–2:2006, Table 5;



legs of multi-leg slings are attached to the container pad eyes without twisting of the legs at the master link.

16.2 Inspection report When, in the opinion of the inspector, the correct lifting set has been properly attached to the container, a report shall be issued containing the following information (as a minimum): 

container identification (including owner’s container number);



sling and shackle identification numbers;



name of owner;



report number;



rating (R) of the container;



WLL of the lifting set;



SWL of the shackles;



statement that the lifting set has been selected in accordance with the standard, and is installed correctly;



name of organization, name of the person and authentication by the person carrying out the inspection/ examination or test either by signature or other secure means;



date of report.

NOTE report.

This report may be combined with the container inspection report and/or the lifting set examination

16.3 Record keeping The owner shall retain the report until such time as the lifting set is removed or replaced.

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Specific Accreditation Criteria

ISO/IEC 17025 & ISO/IEC 17020 Application Document Infrastructure and Asset Integrity - Annex

Lifting equipment assessment

July 2018

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© Copyright National Association of Testing Authorities, Australia 2013 This publication is protected by copyright under the Commonwealth of Australia Copyright Act 1968. NATA’s accredited facilities or facilities seeking accreditation may use or copy this publication or print or email this publication internally for accreditation purposes. Individuals may store a copy of this publication for private non-commercial use or copy a reasonable portion of this publication in accordance with the fair dealing provisions in Part III Division 3 of the Copyright Act 1968. You must include this copyright notice in its complete form if you make a copy of this publication. Apart from these permitted uses, you must not modify, copy, reproduce, republish, frame, upload to a third party, store in a retrieval system, post, transmit or distribute this content in any way or any form or by any means without express written authority from NATA.

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Specific Accreditation Criteria: ISO/IEC 17025 & ISO/IEC 17020 Application Document, Infrastructure and Asset Integrity - Annex, Lifting equipment assessment

Table of Contents Introduction ................................................................................................................ 4 Inspection bodies ....................................................................................................... 5 Testing laboratories .................................................................................................... 5 Accreditation criteria ................................................................................................... 5 6

Resource requirements...................................................................................... 5 Personnel criteria ............................................................................................... 5 Equipment criteria .............................................................................................. 6 Equipment performance checks ........................................................................ 6

Process requirements ........................................................................................ 6 Review of requests, tenders and contracts ........................................................ 6 Procedural criteria .............................................................................................. 7 Records and reports .......................................................................................... 8

References ................................................................................................................. 9 Amendment Table ...................................................................................................... 9

July 2018

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Specific Accreditation Criteria: ISO/IEC 17025 & ISO/IEC 17020 Application Document, Infrastructure and Asset Integrity - Annex, Lifting equipment assessment

Lifting equipment assessment This document provides interpretative criteria and recommendations for the conformity assessment of lifting gear. It is relevant to: • •

inspection bodies working to ISO/IEC 17020 and performing inspection of lifting equipment; and facilities working to ISO/IEC 17025 and conducting testing on lifting equipment.

Applicant and accredited facilities must comply with all relevant documents (refer to NATA Procedures for Accreditation) in the: • •

NATA Accreditation Criteria (NAC) package for Infrastructure and Asset Integrity (ISO/IEC 17025); and/or the NAC package for Inspection.

The clause numbers in this document reflect those of ISO/IEC 17020 and ISO/IEC 17025, but since not all clauses require interpretation the numbering may not be consecutive.

Introduction Lifting and lifted equipment may be subjected to several forms of conformity assessment during its design, fabrication, at the time of supply and/or while inservice. Conformity assessment can involve design verification, verification of construction, application of proof loads, application of breaking loads on samples drawn from a batch, visual inspection of equipment in-service, assessment of functionality and proof loading of equipment in service. With regard to proof load testing, this requires the pre and post test examination of the equipment to establish any deterioration or permanent change in the equipment that is attributable to the application of the load. Inspection is defined as: Examination of a product design, product, process or installation and determination of its conformity with specific requirements or, on the basis of professional judgement, with general requirements (ISO/IEC 17000, Clause 4.3) Testing is defined as: Determination of one or more characteristics of an object of conformity assessment according to a procedure (ISO/IEC 17000 Clause 4.2) These definitions are critical in order for NATA to consistently apply and assess a facility against either standard or both. In many cases the distinction between inspection and testing is not reflected in the terminology used in the industry. Accordingly, the following sections allow facilities to determine the appropriate standard, or standards, against which they should seek accreditation for the activities they perform.

July 2018

Page 4 of 9 Bullivants | Page 582 of 692

Specific Accreditation Criteria: ISO/IEC 17025 & ISO/IEC 17020 Application Document, Infrastructure and Asset Integrity - Annex, Lifting equipment assessment

Inspection bodies Facilities accredited to ISO/IEC 17020 may perform functional load testing within the scope of their accreditation when the applied loads are equal to, or less than, the working load limit of the equipment under inspection. Loading of items in excess of the working load limit (WLL) (so-called “proof” loading) is outside the scope of accreditation for inspection bodies, except where the specified technical documents explicitly require ongoing verification by loading above the WLL during in-service inspections. Facilities must be accredited to ISO/IEC 17025 to be able to issue reports under their scope of accreditation for all other proof loading tests above the WLL. The scope of accreditation of inspection bodies who conduct functional load testing will include a statement that such load testing is limited to loads below and including the WLL of the equipment under inspection. Where the exception is relevant, the scope of accreditation will explicitly identify the relevant technical documents used.

Testing laboratories Facilities accredited to ISO/IEC 17025 are able to examine equipment before and after testing and, if appropriate, may reject equipment on the basis of examination only. However, acceptance of equipment as fit for service without subjecting the equipment to a load test (i.e. acceptance by inspection only) is outside the scope of accreditation for testing facilities. Such facilities must also be accredited to ISO/IEC 17020 in order to issue reports under their scope of accreditation for this work.

Accreditation criteria The following information sets out the accreditation criteria, recommendations and guidance relating to Personnel, Equipment, Product-specific criteria and processes / procedures within the facility.

Resource requirements

Personnel criteria ISO/IEC 17020 Clause 6.1; ISO/IEC 17025 Clause 6.2 Vision tests All personnel involved in the assessment of lifting gear must satisfy the following requirement for visual acuity every two years. The person shall be able to demonstrate clear near vision (corrected or uncorrected) by being capable of reading a row of letters of sufficiently fine print (Jaeger No. 1 or equivalent type, or finer) at a distance of 300 mm. This requirement is based upon AS 3978. Colour vision may also be relevant and a one-off confirmation of colour vision performance should be conducted and records kept.

July 2018

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Specific Accreditation Criteria: ISO/IEC 17025 & ISO/IEC 17020 Application Document, Infrastructure and Asset Integrity - Annex, Lifting equipment assessment

Equipment criteria ISO/IEC 17020 Clause 6.2; ISO/IEC 17025 Clause 6.4 Records of proof load determinations for ancillary equipment used for conducting tests (e.g. rings, links, chain) must be kept. Regular inspections of the equipment should also be undertaken. These items should be marked so as to prevent any possible confusion with similar equipment provided by clients. Where rigs are needed to facilitate handling of items for testing or inspection (e.g. container stands, reaction frames), the facility should hold records identifying a working load limit for such rigs.

Equipment performance checks ISO/IEC 17020 Clause 6.4; ISO/IEC 17025 Clause 6.4.5 Equipment used for proof loading shall be capable of maintaining a load for 10 seconds to within the specified force tolerance or, if not otherwise specified, then to within 5% (which equates to Class C, as defined within AS 2193). Equipment used for breaking load tests shall be capable of force measurement to an accuracy of within 1% (which equates to Class A, as defined within AS 2193. Facilities must ensure that where methods writing bodies have included equipment calibration and checking intervals in standard methods that these intervals must be followed if the methods are covered by the accreditation. Facilities should refer to the guidance documents available for equipment (and NATA’s General Equipment Calibration and Checks, General Equipment Table) for further information on calibrations and checks on equipment.

Process requirements

Review of requests, tenders and contracts ISO/IEC 17025 Clause 7.1; ISO/IEC 17020 Clause 7.1 Customers’ requests shall be reviewed to ensure that the characteristics, which are to be inspected, measured or tested, together with any acceptance criteria, are clearly and unambiguously stated. Where the item of lifting gear is required to be accompanied by engineering computations (e.g. it is not covered by an Australian or recognised overseas standard1) the facility shall check to ensure that all necessary information has been supplied before performing any conformity assessment work. The review shall include physical, personnel and information requirements and resources and shall confirm that personnel have the skills and expertise necessary for the satisfactory performance of the work requested. Note1: ‘Recognised overseas standard' is a standard published by a recognised standards writing body such as international/national standards organisations, specifying organisations such as the American Society for Testing and Materials (ASTM) and government agencies.

July 2018

Page 6 of 9 Bullivants | Page 584 of 692

Specific Accreditation Criteria: ISO/IEC 17025 & ISO/IEC 17020 Application Document, Infrastructure and Asset Integrity - Annex, Lifting equipment assessment

Safety-related issues shall be considered during the review of requests, with particular attention to matters relating to access, loading and the possible consequences of failure.

Procedural criteria ISO/IEC 17020 Clause 7.1; ISO/IEC 17025 Clause 7.2 & 7.4 Fibre rope slings Accreditation is available for proof tests upon fibre rope slings. The facility seeking accreditation must develop a testing procedure for the items under test. Specific matters, for example loading rates, must be considered. Plate clamps Accreditation is available for proof tests upon plate clamps. AS 4991 gives specific details for the testing of plate clamps. The hardness of the test plates used shall either be determined by a NATA accredited facility (or a facility accredited by an accreditation body signatory to the ILAC Mutual Recognition Arrangement) or shall be determined in-house with supporting records. If in-house hardness testing is conducted the hardness testing equipment shall be calibrated and the requirements for hardness testing as detailed in the Specific Accreditation Criteria: Manufactured Goods Annex - Physical Testing of Metals must be met. The condition of test plates shall be examined regularly to ensure their continued suitability (i.e. have not been excessively damaged by plate clamps). The facility shall document acceptance criteria for the test plates and hold records of the condition checks and maintenance / replacement of test plates. These items should be marked so as to prevent any possible confusion with similar equipment provided by clients. Serial hoists Operational tests on serial hoists shall include both raising and lowering under load. When using a hydraulic system the load shall be maintained between (-5%, +20 %) during the lowering and raising procedure. Slings The legs of multi-legged slings shall be tested in accordance with the relevant standard taking into consideration the operating angle. The head link shall not be overloaded if legs are tested simultaneously using a load equalising device. When calculating the force to be applied consideration shall be given to the resolution of forces through the load equalising device. Determination of centre of gravity of structures/weighing of structures In addition to the usual requirements associated with procedures, procedures describing the determination of centre of gravity and/or weight of structures must detail: • • •

how allowance for friction is made; how the lift is undertaken; the type of beam to be used; and

July 2018

Page 7 of 9 Bullivants | Page 585 of 692

Specific Accreditation Criteria: ISO/IEC 17025 & ISO/IEC 17020 Application Document, Infrastructure and Asset Integrity - Annex, Lifting equipment assessment

•

how allowance for environmental influences is made.

Marking and identification of items In the case of small items it may not be feasible to tag, mark or otherwise identify each item. The client shall be consulted to establish protocols for handling small items. Where the identification of an item is refreshed, changed or revised (e.g. by retagging, changing colour dots or replacement of data plates) all changes must be reported to the client. Testing parameters Critical components shall be marked or measured to ensure permanent deformation can be quantified. If measurements are made they must be recorded. There are a number of methods for determining deformation of lifting equipment. The preferred method must be identified in facility documentation, either under a general testing procedure or within product-specific testing procedures. When an item is submitted for proof testing and it is not covered by an Australian standard, or a standard written by another standards writing body, it must either be accompanied by engineering computations or be permanently marked with its capacity, safe working load or working load limit, as applicable. Where a permanent marking on the item is the basis for determination of proof load or force, the customer shall provide the facility with detail of the authorisation for the permanent marking, and this basis shall be stated on both test record and report. Where this detail is not available, the work cannot be covered by the scope of accreditation. On-site testing Accreditation is available for on-site proof load testing of items and fixtures. The facility must possess suitable equipment and procedures. The scope of accreditation is structured to reflect the on-site testing capability of the facility.

Records and reports ISO/IEC 17020 Clauses 7.3 & 7.4; ISO/IEC 17025 Clauses 7.5 & 7.8 When testing individual components of an assembled product (e.g. multi-legged sling) or a number of items of the same description, the actual load applied to each component or item must be recorded in test records. Test reports may detail only the overall force or load applied. For tests such as proof tests on items, the design and manufacture of which are not covered by an Australian or recognised overseas standard, the test record and report shall each state the test configuration and the basis upon which the test load or force, and the method of its application is derived.

July 2018

Page 8 of 9 Bullivants | Page 586 of 692

Specific Accreditation Criteria: ISO/IEC 17025 & ISO/IEC 17020 Application Document, Infrastructure and Asset Integrity - Annex, Lifting equipment assessment

References This section lists publications referenced in this document. The year of publication is not included as it is expected that only current versions of the references shall be used. Standards AS 2193

Calibration and classification of force measuring systems

AS 3978

Non-destructive testing - Visual inspection of metal products and components

AS 4991

Lifting devices

ISO/IEC 17000

Conformity assessment - Vocabulary and general principles

ISO/IEC 17020

Conformity assessment – Requirements for the operation of various types of bodies performing inspection

ISO/IEC 17025

General requirements for the competence of testing and calibration laboratories

NATA Publications NATA Accreditation Criteria (NAC) package for Infrastructure and Asset Integrity (ISO/IEC 17025) NATA Accreditation Criteria (NAC) package for Inspection General Accreditation Guidance

General Equipment - Calibration and Checks, General Equipment Table

Specific Accreditation Criteria

Manufactured Goods Annex - Physical Testing of Metals

Amendment Table The table below provides a summary of changes made to the document with this issue. Section or Clause Whole document

July 2018

Amendment The document has been reviewed, editorially amended and updated to include ISO/IEC 17025:2017 clause numbering. Additionally, equipment requirements from the former Mechanical Testing Application Document Annex A which were omitted have now been incorporated.

Page 9 of 9 Bullivants | Page 587 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS Controlled Process:

Yes.

Created:

August 2020

Modified:

2nd September 2020

Release Date:

24th August 2020.

Next Review:

36 months from release, earlier if required.

Status:

New Release.

Prepared By:

Andrew Taylor, John Poolman

Approved By:

Andrew Taylor, John Poolman

Applicability:

All of Bullivants.

Document Revision History Revision #

Date

Revision Description

Revision By

0613

Service Agreements

Brett Lieurance

0619

IT-LA Testing Lifting Appliances

Brett Lieurance/ Andrew Taylor

IT-VI Visual Inspection of Rigging Products using checklist

Brett Lieurance/ Andrew Taylor

0220

IT-TC Test Certificates

Andrew Taylor

0312

Visual Inspection of Synthetic Items marked with pens

Andrew Taylor

Inspection, Examination and Testing of Offshore Lifted Equipment and Associated lifting sets

August 2020

Updated to new Bullivants Procedure Template. Replaces IT-VI Visual Inspection of Rigging Products using checklists and IT-TC Test certificates.

September 2020

0418

Updated to the Bullivants Procedure

Andrew Taylor/John Poolman

Andrew Taylor

Bullivants | Page 588 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS

Table of Contents Section

Content

Page

Purpose / Objective

Applicability

References

Definitions

Safety

Personnel

Reponsibilities

Procedure

Measuring and Marking

Visual Inspection

Acceptance Criteria

Inspection and Record Retention

Visual Inspection Checklists

Test Certificates

Service Agreements

Customer or Purchaser Supplied Products

Despatch Dockets (Pinks or Pick slips)

Manufacturing Orders

Subcontracting Tests

Test Failure

Corrections

Recall

Integrity

Confidentiality

Undue Influence

Identification

Branch Prefix

Service Agreement Marking

Appendix A

Appendix B

Appendix C

Appendix D

Appendix E

Sign Off Page

Bullivants | Page 589 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS 1.

Purpose / Objective This instruction applies to visual inspection, proof and destruction testing, where specified, magnetic particle inspection of lifting appliances and height safety systems and generation of test reports/certificates.

Applicability All of Bullivants team members and facilities.

3. References • • • • •

• • • • • • • • • • • • • • • • • • • • • • • • • • •

ISO9001 - Quality Management Systems – Requirements ISO9712 - Non-destructive testing - Qualification and certification of personnel ISO14001 - Environmental Management Systems – Specification with guidance for use ISO/IEC 17020 - General criteria for the operation of various types of bodies performing inspection ISO/IEC 17020 &17025 - Application Document Infrastructure and Asset Integrity – Annex Lifting Equipment AS 1353.1 - Flat Synthetic Webbing Slings AS1353.2 - Flat synthetic webbing slings care and use AS1380.1,2 - Fibre rope slings AS1418.1 - Crane, hoist and winches – general requirements AS1418.2 - Cranes, serial hoist winches AS1418.3 - Crane, hoist and winches – Bridge , Gantry, Portal & Jib AS1418.17 - Crane, hoist and winches – Design & construction of workboxes AS1418.18 - Crane, hoist and winches – Crane runways & monorails AS1554 - welding steel structures AS1657 - Fixed Platforms, Walkways, Stairways and Ladders AS1666.1&2 - Wire rope slings – Production and care and use AS1891.1-4 - Industrial Fall Arrest systems and devices AS1892.1,2,3,5 – Portable Ladders AS2089 - Sheave blocks for lifting purposes AS2317.1 - Collared eyebolts AS2318 - Swivels for hoists AS2319 - Rigging screws and turnbuckles AS2321 - Short link chain for lifting purposes AS2359 - Powered Industrial Trucks (Forklift Attachments) AS2550 - Cranes, Hoists and Winches – Safe Use AS2693 - Vehicle Stands AS2740 - Wedge type sockets AS2741 - Shackles AS2759 - Steel Wire Ropes – Use, Operation & Maintenance AS3569 - Steel Wire Ropes – Product Specifications AS3711.1 - Freight containers classifications, dimensions and ratings AS3775.1 - Chain Slings for Lifting Grade T(80) and Grade V(100)

Bullivants | Page 590 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS • • • • • • • • • • • • • • • • • • • • • • • • •

AS3775.2 - Chain Slings for Lifting Grade T(80) and Grade V(100) Care and use AS3776 - Lifting components for Grade 80 and 100 chain slings AS3777 - Shank hooks and large eye hooks (max 60T) AS3785.7 - Underground Mining – Shaft Equipment - Sheaves AS3850.1 - Concrete Lifting Attachments AS4344 - Transport Chain and Components AS4345 - Transport Fibre Rope AS4380 - Transport Webbing and Components AS4801 - Occupational health & safety management systems AS4100 - Steel Structures AS4497 - Synthetic Roundslings AS4722 - Passenger Ropeways & Passenger Conveyors AS4797 - Stainless Steel Chain for lifting Purposes AS4812 - NDE and discard criteria for wire rope in winding systems AS4991 - Lifting Devices AS5532 - Manufacturing requirements for single point anchor device DNV 2.7-1 - Certification notes No. 2.7-1 for Offshore Containers ASEN12079.1-3 - Offshore Containers – Design, construction, testing, inspection & marking Marine Orders Part 32 and 44 Local statutory requirements – Workcover, DME etc (changes depending on which state) Bullivants BPM Manual Bullivants – Visual Inspection Checklists ( see WIS Portal or BV SharePoint/Quality) Bullivants - Record of test forms and test certificate templates Bullivants Procedure – NDT of Products (IT-NDT2) Bullivants Procedure – Customer Supplied Product

Bullivants | Page 591 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS 4.

Definitions

Delegated Delegated Signatory (DS):

Team members who are approved by the Delegating Authority to approved test and visual certificates on behalf of Bullivants for work covered by the NATA scope of accreditation.

DoA:

Delegation of Authority.

NATA:

National Association of Testing Authorities.

Scope of Accreditation:

NATA defined testing, inspection and related services covered by the accreditation.

Customer’s Representative: Checklist: Inspection: Lifting Appliance: MPI: NDT: Service Agreement:

Site Memorandum: WLL MO

Site contact and sole arbiter of customer’s requirements Hardcopy or electronic list of inspection criteria and results Examination of a product to determine conformity with specific requirements Equipment such as: wire rope slings, chain, fittings, synthetic slings, nets, containers, baskets, frames, racks, lifting, spreader beams, height safety equipment and load restraint devices Magnetic Particle Inspection Non-Destructive Testing Agreement between Bullivants and the customer setting out terms, conditions and scope of work which must be signed by both parties before work commences and at the end of the job Document which details any variations to terms, conditions or scope of work whilst work is in progress. Should also be used to record any significant occurrence, this can also be recorded on a Service Agreement form. Working load limit ASW Manufacturing Order

5. Safety Testing shall always be conducted with the safety of personnel and protection of the equipment in mind. Personnel conducting testing off site shall adhere to company policy including site Service Agreements, JSA and Risk Assessments. Shall be inducted for site specific/statutory safety requirements. Where Australian Standards or codes require equipment to be elevated to excessive heights (i.e. AS1418.17, clause 4.2 – raising workboxes to 3m above the ground), duty of care should be exercised by only lifting the load so it just clears the ground to verify the integrity of the lifting appliance. Use of customer overhead cranes to assist during inspections shall be by a qualified person with a minimum of RIIHAN305D Operate a Gantry or Overhead Crane.

Bullivants | Page 592 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS 6. Personnel Personnel who have successfully completed training in the applicable procedure as depicted in their competency matrices shall conduct work covered in this procedure. For all methods in which certification are held, the person shall: • Choose the applicable visual inspection method or testing technique and procedure to be used • Set up, calibrate equipment and verify the correct functioning of test equipment and test materials • Interpret and evaluate results in accordance with applicable codes, standards and specifications • Record the results of tests and equipment serial numbers used • Have an eyesight test to confirm their natural or correct near distance visual acuity, as follows: • Mechanical – to Jaeger 1 at 300mm every 2 years as per ISO17025 • VI (Visual Inspection) and NDT - to Jaeger 1 at 300mm every year is as per ISO17020 7. Responsibilities Work covered by this instruction shall be conducted by personnel who have successfully completed training in this procedure, as depicted in their skills matrices and denoted by a signed copy of this instruction in their respective personnel file. Other functions having direct responsibilities in the body of the procedure are Approved Signatories and the Authorised Representative. A Delegated Signatory is qualified to perform and direct all ‘testing as per the sites scope of accreditation’ as depicted by NATA. 8. Procedure 8.1. General The processes covered by this procedure shall comply with the inspection and testing requirements specified by one or more of the documents listed in the ‘References’ section. Personnel shall ensure inspection & test equipment is stored and transported in such a manner that will not invalidate the accuracy of the results. Inspection results shall be captured either BEAM (Bullivants Electronic Asset Management) or Visual Inspection checklists refer Appendix. D. 8.2. Contract Review Documentation is required to provide an assurance that the lifted appliance has been designed and fabricated to approved lifted equipment standards. If it is not available to support the integrity of the item, it shall not be approved for use and the customer must be advised. Acceptable documentation shall be provided in the form of a ‘certificate of conformity, engineering drawing, a design verification statement or a statement by the designer.’ If the item has been supplied by a customer and is not covered by one of the documents listed in section 2 of this procedure, a written work practice or instruction shall be sought. If this cannot be done then the work shall be declined.

Bullivants | Page 593 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS 8.3. Inspection & Testing Process 8.3.1. Refer to the flowchart in this procedure, Appendix. E, to determine the correct inspection and test methodology in conjunction with the relevant standard or specification. 8.3.2. Prior to commencing any test the appliance shall be visually inspected in order to determine as far as possible, that the lifting points and general structure are free from corrosion, wear or any other deleterious conditions. 8.3.3. If any defects are found the appliance shall not be tested, but referred to the Customer’s Representative. 8.3.4. The appliance shall, as far as possible, be rigged, loaded and lifted in the same manner, as it will be used in service with the test weights evenly distributed across the floor. For beams and spreaders bars, dedicated units or weights may be suspended below in a suitable configuration. 8.3.5. Test load shall be applied and held for the time specified in the relevant standard or specification. 8.3.6. If certified weights are unavailable, a calibrated load cell shall be used. 8.3.7. Measurements that are required to be taken whilst the appliance is loaded (i.e. measuring deflection of a beam under load), must be done so as not to compromise the safety of all concerned. Use of laser levels, string lines enables measurements to be taken accurately.

8.3.8. After the test load has been removed the appliance shall be inspected to determine the nature and extent of any damage incurred during the test, using acceptance criteria from the appropriate standard. 8.3.9. The extent of any other damage shall be noted and if necessary appropriate repairs to the damaged areas shall be conducted only after full consultation and agreement with the Customer’s Representative (refer to the CSP procedure). 8.3.10. When required by the customer, standard or specification etc, 100% of the welds on the lifting points shall be subjected to a magnetic particle inspection (refer to Bullivants Procedure – NDT of Products to ISO17025). 8.3.11. If any welds fail the MPI, they shall be repaired and retested as per clause 7.3.9. Note, it may be a requirement of the customer, standard or specification etc, to conduct pre and post MPI testing of the appliance – this should be determined before work is commenced as part of the contract review process. 8.3.12. If no damage is evident or has been rectified as per procedure and the appliance has passed all the necessary requirements, a test certificate can be issued as per the applicable standard.

Bullivants | Page 594 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS 8.3.13. Non-standard - Grade 120 Alloy Chain Slings If the assembly is made from Grade 120 materials (chains and fittings) of which there is no Australian Standard, the test certificate must note as follows in the comments section. Test Method is in accordance with Bullivants internal procedure IT-LA, Inspection and Testing of Lifting Appliances which calls for use of test methods as per AS 3775 - AS 3776 and the Chain & Fittings values are provided via the respective manufacturer’s catalogue. That allows for conformance to an approved method of test and covers the chain and fittings which currently do not have an applicable local standard. 8.3.14. For testing girder trolleys refer to Section 9 of AS1418.2. 8.3.15. Proof and deflection tests for monorails, bridge cranes and jib cranes shall be conducted in accordance with the relevant section of AS1418.18 (section 5.13). Note when a mono rail is continuously supported, the test shall be conducted where “L” is the largest distance between adjacent supports. The proof test load shall be 100% of the WLL, unless a commissioning test at 110% of the rated capacity. The deflection shall not exceed L/500 expressed as millimetres. NB: When load-testing monorail beams the location of the application of the test load must be detailed. 9.

Marking and Measuring A method to measure included permanent deformation shall be applied as per the relevant Australian Standards for the product. This consists of marking the item of lifting equipment in two locations on the body the distance between the marks. After applying the proof- load for a time of not less than 1 min, the load from the lifting devices, and the distance between the marks shall be re measured dimensions compared to the original. Any permanent set in the dimension as required in the relevant standard. The lifting device shall receive a further visual or non-destructive testing competent person for evidence of flaws or defects following the test. To illustrate further refer to Appendix. A, B & C or from the Australian Standard for Shackles and Hooks. For marking of other products, refer to relevant Australian Standards.

10.

Visual Inspection Using the applicable NATA ISO17020 checklist/s or BEAM as a guide, conduct the inspection. Where the checklist or BEAM has been requested as a record, please ensure all details are completed. Where the item is not able to be inspected, or is not required to be inspected, the section should be marked “n/a” (not applicable).

11.

Acceptance Criteria Acceptance criteria are obtained from either the reference standard or manufacturer’s specifications. The latter may not be available for older models, so the general requirements of the standard nominated in the checklist or BEAM will be used as a guide.

Bullivants | Page 595 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS 12.

Inspection Records Retention All inspection reports must be retained for a minimum of four years from the date of issue of the inspection report. Statutory and contractual obligations may specify longer record retention periods. The issuing branch must ensure the confidentiality of all customer information obtained in the course of its inspection activities, including the protection of proprietary rights.

13.

Visual Inspection Checklists Refer to Appendix. D

14.

Test Certificates

14.1. General Test certificates are normally generated from four (4) discrete areas: • Manufacturing orders • Sales Orders, detailed on Pick Lists (or more commonly known as “Pinks”) • Site based Service Agreements • Customer supplied products (CSP) requiring testing These areas form the basis of this procedure for testing products and reporting the results 14.2. The results of each test or series of tests shall be reported accurately, clearly, unambiguously and objectively, and in accordance with any specific instructions of this procedure or referenced standard. The test certificate shall be generated on a defined format available on the G drive under each branch/management systems folder, the format shall comply with content as per relevant Australian standards and logo requirements and ISO 17025/17020. 14.3. Each test report or certificate shall include (a) A title (b) The name and address of the laboratory and the location where the tests are performed if different from the address of the laboratory. If the testing facility is testing products under the scope of their NATA accreditation then a NATA certificate can be issued within the scope of the accreditation. The certificate shall comply with NATA Logo requirements, as outlined in NATA Rules available on the NATA web site. 14.4. Only approved signatories can sign and approve NATA test certificates. 14.5. If testing personnel are awaiting approval or their approval status has been withheld or suspended, then they shall not authorise NATA endorsed test certificates. 14.6. For those branches that do not have NATA accreditation [or NATA accreditation for a particular scope of test(s)] then, an unendorsed (i.e. non- NATA) test certificate can be signed by a competent person, who has completed training for the type of test, as depicted in their skills matrices.

Bullivants | Page 596 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS 14.7. Approved signatories shall be aware of relevant sections of the NATA Rules document. 14.8. Where products are not covered by the relevant Australian Standard, the test certificate shall refer to in house procedure or customer’s test specifications. 14.9. Interpretation and Opinion In addition to the requirements listed above, test reports shall, where necessary for the interpretation of the test results, include the following: • • • •

deviations from, additions to, or exclusions from the test method, standards and information on specific test conditions ; additional information which may be required by specific methods, customers; When opinions and interpretations are included, the Delegated Signatory shall document the basis upon which the opinions and interpretations have been made. Opinions and interpretations shall be recorded separate to the test report normally in a cover letter or note accompanying.

NOTE: Opinions and interpretations provided with a test report may comprise, but not be limited to, the following: • an opinion on the statement of compliance/non-compliance of the results with requirements; • fulfilment of contractual requirements; • recommendations on how to use the results; • guidance to be used for improvements. NOTE: In many cases it might be appropriate to communicate the opinions and interpretations by direct dialogue with the customer. Such dialogue should be written down on the service agreement. 15.

Service Agreements

15.1. When products are to be tested off site (i.e. in the field or at a customer’s premises), a Service Agreement form is utilised. The scope of the work is recorded, agreed to and signed by the customer before commencing work and after work completion. Note, if variations to the scope of work are required post agreement, then Site Memorandum forms or Service Agreement forms are used to record the variations and subsequent approval from the customer before proceeding. This is a very important step, if approval to variations are not sought and agreed to, and then problems can arise when invoicing the customer. 15.2. For traceability, the Service Agreement and or other appropriate number is used to identify each tested item and is stamped on for each item as depicted in clause 7.4.2. 15.3. Note, if Customers wish to use their own identification system, then use this in lieu of clause 7.5.2 and use this as the product reference, ensuring it is recorded on the Service Agreement/Site Memorandum. 15.4. If there is insufficient space to record all the information (i.e. if there are multiple/various items to test), record the information on the “Record of Test Sheets” and attach them to the Service Agreement. 15.5. When the work has been completed, ensure all the appropriate information is legible and recorded on the appropriate forms, including the details in clause 7.4.2. 15.6. The Service Agreement and attachments can then be used to generate a Pick List.

Bullivants | Page 597 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS 15.7. All information is then transferred to the “Certificate of Test” database, ensuring the Service Agreement number is transferred to the “Service Agreement Field” and the “ID Marks Field” in the Test Certificate Database to ensure complete traceability. 15.8. The certificate of test report is then presented to the Delegated Signatory for final review and signing, the location of the test must be noted on the certificate, including at customer’s premises. 15.9. After signing, a copy is filed and the original is forwarded (with the goods or by mail) in accordance with the customer's instructions. 16.

Customer or Purchaser Supplied Products

16.1. When Customer supplied products are to be tested, a “Customer Supplied Product “(CSP) form is used. A Sales Order is then raised to control the CSP. When all items used and work to be done is known, a Pick List is printed. The Sales Order number is then recorded on the CSP card. 16.2. For traceability, the unique Job No (i.e. the CSP or other appropriate number) is used to identify each tested item and is stamped on for each item as depicted in clause 7.16. 16.3. Note, if Customers wish to use their own identification system, then use this in lieu of clause 7.7.2 and use this as the product reference, ensuring it is recorded on the CSP card/Pink. 16.4. If there is insufficient space to record all the information (i.e. if there are multiple/various) items to test, record the information on the “Record of Test Sheets” and attach them to the CSP. 16.5. When the work has been completed, ensure all the appropriate information is legible and recorded on the appropriate forms, including the details in clause 7.4.2. 16.6. The CSP and attachments can then be used to generate a Pick List. 16.7. All information is then transferred to the “Certificate of Test” database, ensuring the Job No is transferred to the “CSP No Field” and the “ID Marks Field” in the Test Certificate Database to ensure complete traceability. 16.8. The certificate of test report is then presented to the Delegated Signatory for final review and signing. 16.9. After signing a copy is filed and the original is forwarded (with the goods or by mail) in accordance with the customer's instructions. 17.

Despatch Dockets (Pinks or Pick slips)

17.1. The Warehouse Supervisor or other Approved Signatory reviews the computer generated pick slip on which the Sales Representative has stated customer's testing requirements. 17.2. The Technician carries out the test as detailed in the appropriate Standard or Specification under the paragraph headed 'Proof Load' or 'Proof Testing'. 17.3. Record all test information on the “Record of Test Sheets” and attach them to the Pink. 17.4. For traceability, the unique Sales Order No on the Pink is used to identify each tested item and is stamped on each item as depicted in clause 7.16. 17.5. On satisfactory completion of the test, the test information is transferred to the “Certificate of Test” database, ensuring the Sales Order number is transferred to the “Sales Order No” box. The certificate of test report is then presented to the Delegated Signatory for final review and signing. 17.6. After signing, a copy is filed and the original is forwarded (with the goods or by mail) in accordance with the customer's instructions.

Bullivants | Page 598 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS 18.

Manufacturing Orders

18.1. Manufacturing Orders are generated to make frequently purchased assemblies or made up items for stock. It includes all the relevant testing information typically found on pink slips, for further details refer to work order procedures. 18.2. The Technician conducts the test as detailed in the appropriate Standard or Specification under the paragraph headed 'Proof Load' or 'Proof Testing', recording all the relevant information, (including the details in clause 7.16.), on record of test sheets.. 18.3. For traceability, the unique Manufacturing Order No is used to identify each item tested and is stamped on each item as depicted in clause 7.16. 18.4. On satisfactory completion of the test, the test information is transferred to the “Certificate of Test” database, ensuring the Manufacturing Order number is transferred to the “Manufacturing Order No” box. 18.5. The certificate of test report is presented to the Delegated Signatory for final review and signing. As there is no customer until the goods are sold, the copy is filed and the original is attached to the goods. The certificate must be attached to the goods in a manner that will ensure its integrity is maintained. 19.

Subcontracting Tests If testing is required to be subcontracted out, the Customer shall be notified and approval shall be granted before accepting the order.

20.

Test Failure In the event of an article failing the required test, the product will be remade or the customer notified. The failed product must then be tagged ‘nonconforming product’. The failure shall be recorded on the Service Agreement, CSP or Pink forms. The Delegated Signatory shall review and implement the appropriate action, including raising a CAR if necessary.

21.

Corrections Test documents shall be free of corrections/erasures. When crossing out is unavoidable, the person making the change shall initial and date each correction and the change(s) must not obliterate the original data.

22.

Recall If after the issuing of a document, test data is found to be invalid the original report shall be withdrawn and replaced by one marked ‘Replacement for Report No.’. The replacement report will be issued with new number with reference to original number and filed with the original so as to clearly identify the correction and revision status. Customers shall be promptly advised in writing of any event that casts doubt on a test result. The re-issued document needs a comment as to “what was amended and the reason for the change”.

23.

Integrity When electronic systems are used to store records, integrity must be maintained. One original certificate and one copy (both bearing manuscript signatures) shall be produced at the time of relevant test. If a further copy is required (e.g. by a customer at a later date) the filed copy shall be photocopied. All original test data shall be retained for a period of 4 years.

Bullivants | Page 599 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS 24.

Confidentiality The information contained on any test certificate shall be considered confidential between the Company and the customer. Any information concerning any test certificate requested by a third party shall only be given with the customer's written permission.

25.

Undue Influence Should any attempt be made from any source to influence the result of any test, the test shall be discontinued until such influence is removed. In the advent of conflict of interest (i.e. when a company representative is involved in other areas as well as testing), testing personnel shall ensure the integrity of the test is not compromised.

26.

Identification The following are suggested prefix be used to identify the test item(s) and the branch that performed the test. As and when required, the branch prefix can be changed to suit the branch numbering requirements. In such case, the branch shall uniquely identify each test certificate number and shall correlate to the branch numbering system.

27.

Branch Prefix: • Adelaide • Brisbane • Bunbury • Cairns • Darwin • Emerald • Gladstone • Kalgoorlie • Mackay • Mt Isa • Newcastle • Perth • Port Hedland • Sydney • Toowoomba • Townsville • Melbourne • Wollongong

BA BB BBU BC BD BE BG BKA BM BI BN BP,BVI,DT BPH BS BZ BT BV BW

Bullivants | Page 600 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS 28.

Service Agreement Marking Depending on the source, each item should be stamped with the appropriate number as depicted below: Service Agreement – BV1863/1 • BV • 1863 •1

- Branch and Location (i.e. Bullivants Victoria) - Unique Service Agreement Number - first item of test, subsequent items are stamped 2, 3, 4 etc.

Customer Supplied Product – BV22500/2 • BV • 22500 •1

- Branch and Location (i.e. Bullivants Victoria) - Unique Job Number on each Customer Supplied Product form - first item of test, subsequent

Despatch Document (Pink) – BV1134859/3 • BV - Branch and Location (i.e. Bullivants Victoria) • 1134859 - Unique Sales Order number •1 - first item of test, subsequent items are stamped 2, 3, 4 etc. Manufacturing Orders – BV11300120/3 • BV • 300120 •1

- Branch and Location (i.e. Bullivants Victoria) - Unique Work Order number - first item of test, subsequent items are stamped 2, 3, 4 etc.

Appendix. A Shackle bodies shall be permanently and legibly marked with the information required by AS 2741, the marking being either raised or indented. Where the marking is indented, the marks shall not have sharp edges nor reduce the strength of the shackle. The marking should be located in accordance with Figure shown below.

Bullivants | Page 601 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS Appendix. B When determining the permanent set property of a hook type lifting component as of AS 3776, before any loading has been applied to the hook type lifting component, a center punch mark A shall be applied on the point of the hook and an arc B centered on A shall be scribed on the load centerline of the shank of hook (see Figure below). Then the minimum proof test force as of AS 3776 shall be applied and removed. After removing the force, an arc C of the same radius shall be similarly scribed. If a variance is confirmed, then you must refer to the manufacturer’s specification and verify that the movement is less than 1% of the ‘original dimension’, not 1% of the scribe mark.

Appendix. C When determining the permanent set property of a lifting clutch as of AS 3850, before any loading has been applied to the hook type lifting component, centre punch marks at A, B, C, D and E shall be applied on the body and measure from A to B & C, then measure from D to E across clevis and record. Record these measurements pre and post the proof test to check for permanent set or movement at all.

E B D

Bullivants | Page 602 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS Appendix. D - Visual Inspection checklists 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24 4.25 4.26 4.27 4.28 4.29 4.30 4.31 4.32 4.33 4.34 4.35 4.36 4.37 4.38 4.39 4.40 4.41 4.42 4.43 4.44 4.45 4.46 4.47 4.48 4.49

Form VI-1: Wire Rope Slings, Swaged/Hand Spliced Checklist Form VI-2: Fibre Rope Slings Checklist Form VI-3: Chain Slings Checklist Form VI-4: Chain Blocks/Lever Hoists Checklist Form VI-5: Sheave Blocks Checklist Form VI-6: Shackles Checklist Form VI-7: Flat Webbing & Round Synthetic Slings Checklist Form VI-8: Collared Eyebolts and Eyenuts Checklist Form VI-9: Eye Hooks Checklist Form VI-10: Swivel Hoist Hooks Checklist Form VI-11: Shank Hooks Checklist Form VI-12: Containers Checklist Form VI-13: Gas Racks & Frames Checklist Form VI-14: Magnets Checklist Form VI-15: Billy Pugh Checklist Form VI-16: Trolleys Checklist Form VI-17: Plate Clamps Checklist Form VI-18: Master Links Checklist Form VI-19: Girder Clamps Checklist Form VI-20: Harness and Lanyard Checklist Form VI-21: Floor Cranes (inc. Hydraulic) Checklist Form VI-22: Lifting Beams and Spreaders Checklist Form VI-23: Loadbinders Checklist Form VI-24: Ladder Checklist Form VI-25: Special Fittings Checklist Form VI-26: Waste Bins Checklist Form VI-27: Manboxes and Workboxes Checklist Form VI-28: Load Restraint Equipment Checklist Form VI-29: Wedge and Spelter Socket Checklist Form VI-30: Tirfor Winch Checklist Form VI-31: Cargo Net Checklist Form VI-32: Spring Balancer and Fall Arrestor Checklist Form VI-33: Anchor Strap and Pole Strap Checklist Form VI-34: Drum Lifter Checklist Form VI-35: Bulka Bag Checklist Form VI-36: Tool Lifting Bag Checklist Form VI-37: Weld on Lugs and Pad Eye Checklist Form VI-38: Concrete Lifting Clutches Checklist Form VI-39: Anchor Points for Height Safety Checklist Form VI-40: Crane Main Hoist & Auxiliary Hoist Checklist Form VI-41: Shell Lifting and Spreader Beams Form VI-42: Shell Crane Lifting Device Form VI-43: Underground Winding Suspension Rope End Caps Form VI-44: Winding Suspension Detaching Hooks Form VI-45: Gangway Brows Form VI-46: Winding Suspension Connection Drawbars Form VI-47: Towing Strops Form VI-48: Water Bags Form VI-49: Esso Wire Rope checklists AUX Main Luff

Bullivants | Page 603 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS 4.50 4.51 4.52 4.53 4.54 4.55 4.56 4.57 4.58 4.59 4.60 4.61 4.62 4.63

Form VI-50: Inspection Checklist for Rescue Bouys Form VI-51: Inspection Checklist for Vehicle Jacks Supports & Stands Form VI-52: Inspection Checklist for Ladsafe Lines Form VI-53: Inspection Checklist for Horizontal Lifeline Systems Form VI-54: Inspection Checklist for Mobile Platform with Horizontal Lifeline Form VI-55: Inspection Checklist for Petzel Rope Access Harness Form VI-56: Inspection Checklist for Hoists ( Air, Electric – Chain or Wire Rope) Form VI-57: Inspection Checklist for Column & Free Standing Jib Cranes Form VI-58: Inspection Checklist for Height Safety Tripods Form VI-59: Inspection Checklist for Gantry Cranes and Overhead Cranes Form VI-60: Inspection Checklist for Concrete Lifting Eyes Form VI-61: Inspection Checklist for Elevator Wire ropes Form VI-62: Inspection Checklist for Portable Ladders used for Fire Services Form VI-63: Inspection Checklist for Luffing, Shuttle and Telechute wire ropes

Bullivants | Page 604 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS Appendix. E Either onsite or off site work

Inspection & Testing

What is the full scope of the Job? Who is doing what? This must be determined before work commences so there is no ambiguity as to who is doing what based on the source (s) of information.

Define the scope of Work

Does the Contract require NATA Inspection and/ or testing

As we are NATA accredited, we must communicate this to the Customer thereby ensuring they understand the costs and benefits (as there is quite a difference in the associated costs). Wherever possible, we should steer the customer to a NATA inspection. If the customer requests a non NATA inspection, then denote this on the Service Agreement Form. This is important, if we provide the customer with a choice they feel more in control and will most likely choose the safer option (if we sell it right).

Use either ISO17020 or ISO17025 if within the scope of supply.

Is the Work to be conducted Off or On Site?

Off

Complete the Service Agreement Form

Is there a relevant International Standard to test the product to?

This form is a Contract with our standard terms and conditions printed on the reverse side. The Customer’s authorized representative must sign this before proceeding, thereby acknowledging and agreeing with the scope of work to be conducted. Refer to the company procedure on “Contract Review”.

On Complete a Sales Order Form (Pink)

Is there a relevant Australian Standard to test the product to?

Inspect & Test in accordance with the appropriate Australian Standard (s)

Inspect & Test in accordance with the appropriate International Standard(s)

Are there variations to the Contract

Revert to the Company’s Liability Statements

Inspect & Test in accordance with company policies

Complete the Site memorandum Form

This form is also a contractual document and must be used when variations to the scope of work are found after completing the Service Agreement form. This also must be signed by Customer’s authorized representative before proceeding, thereby acknowledging and agreeing with the scope of work to be conducted.

Complete and issue NATA certificates

Complete NATA certificates in line with the NATA Rules and ensure they are signed by an authorized signatory. Refer to the company procedure on issuing “Test Certificates”.

Are individual inspection and/or test certificates required?

N Draft and issue Report as per Contract

Complete report in line with the customers requirements (i.e. word document, spreadsheet, dbase) either in hard or soft copy. Be mindful of data security i.e backups (refer to document control procedure)

File copy & end

Bullivants | Page 605 of 692

Procedure:

Inspection,Testing & Reporting – Lifting & Height Safety Equipment

Procedure Number: IT - LAHS

I the trainee …………………………………..................hereby state that I have read and have fully understood this procedure. Trainees Signature …………………………………………………………………………………………… I was trained in the manufacture and testing on the (insert date): ….....…................................................................. I the trainer .....................…………………………... do hereby on behalf of Bullivants Pty Ltd, state that I have trained the above signatory on this day the ...…………………….…............................................... I here by advise that the above signatory has satisfactorily understood and met the requirements of this procedure. They have been deemed competent to continue to the next step. Supervision should be provided until adequate consistency in manufacture and testing has been achieved. Trainers Signature: …………………………………………………………………………………. Supervisors Signature: ……………………………………………………………………………… (NOTE: The employee is not deemed competent to carry out the work unsupervised until the Supervisor signs off this document).

Please detach this page so it can be scanned and uploaded into PeopleSoft by your manager or the BV Training Team

Bullivants | Page 606 of 692

Control of Inspection and Test Equipment

0.0

Document Control

0.1

Table of Contents

0.0

0.2

Document Control ....................................................................................................... 1 0.1

Table of Contents ................................................................................................. 1

0.2

Approval .............................................................................................................. 1

0.3

Amendment Record .............................................................................................. 1

1.0

Purpose ........................................................................................................................ 2

2.0

Scope ............................................................................................................................ 2

3.0

References .................................................................................................................... 2

4.0

Definitions .................................................................................................................... 2

5.0

Description ................................................................................................................... 2 5.1

Introduction ........................................................................................................ 2

5.2

Test Equipment Registration .............................................................................. 2

5.3

Test Equipment Calibration ............................................................................... 2

5.4

Storage and Handling ......................................................................................... 4

5.5

Calibration Record ............................................................................................. 4

5.6

New, Defective and Nonconforming Equipment ................................................. 4

5.7

Equipment Data Files ......................................................................................... 4

6.0 Documentation ............................................................................................................. 5 Approval FUNCTION

POSITION

Reviewed by

Quality and Technical MGR

B.Lierence

Approved by

Learning & Development

A.Taylor

0.3

Page 1 of 5

NAME

SIGNATURE

Amendment Record

Changes made to this procedure since its last revision, which affect its scope or sense. DATE

ISSUE

16/06/06

Original Issue

S Tripathi

27/04/11

0411

Update

B.Lieurance

GSO/ITP/0411

AMENDMENT DESCRIPTION

NAME

INITIAL ST

Control of Inspection and Test Equipment

Page 2 of 5

1.0

Purpose To establish and maintain a system for controlling, calibrating and maintaining inspection, measuring and test equipments.

2.0

Scope This procedure applies to all inspection, measuring and test equipment, including equipment on loan or provided by the customer, which is used to demonstrate the conformance of Company products, assessment of customer-supplied products and test samples, to specified requirement.

3.0

References 1. GSO/BPM 2. ISO/IEEC 17025 3. ISO/IEEC 17020

Business Process Manual Application Document (Mechanical Testing). Application Document (Visual Inspection).

4.0

Definitions 1. Calibration - means a set of operations which establish, under specified conditions, the relationship between values indicated by a measuring instrument or measuring system, or values represented by a material measure, and the corresponding known values of a measurand 2. Responsible Manager (RM) - means a line manager assigned with the overall responsibility for the designated site. Note: A site could be permanent or temporary in full or partial control of the RM.A line manager will usually be a Branch manager, Regional manager, Operations manager or Sales manager, Technical Service Representative (TSR)

5.0

Description

5.1

Introduction All inspection, measuring and test equipment used to demonstrate the conformance of the Company's products, customer-supplied product and test samples to specified requirements shall be controlled, calibrated and maintained. Equipment shall be used in a manner which ensures that measurement uncertainty is known and is consistent with the required measurement capability.

5.2 a)

Test Equipment Registration All purchased, leased or hired test equipment (other than that borrowed from another Branch), must be inspected in accordance with the manufacturers’ guideline or relevant Australian Standard, on receipt, and if delivered into the Company stores, recorded in the delivery day book or an equivalent computerised system. The stores personnel shall forward all details of purchased test equipment to be used, together with a copy of calibration certificate to the TSR or the RM for registration and filing. The TSR or the RM shall, on receipt, record in the register, all details of the test equipment as per the register requirements, including the calibration status of each item of test equipment. The RM shall ensure that Jigs, fixtures, templates or test software used for Inspection and Test are checked to ensure that they are capable of verifying the acceptability of the product and records of such verification recorded in the register

b) c) d)

5.3

Test Equipment Calibration

GSO/ITP/0411

Control of Inspection and Test Equipment

Page 3 of 5

a) Calibration shall be performed in accordance with an established calibration schedule, and against certified equipment having a known valid relationship to nationally recognised standards. Where no such standards exist, the basis used for calibration shall be documented. b) Calibration of test equipment shall preferably be carried out by only NATA or equivalent certified third party calibration originations, satisfying ISO/IEC 17025and or ISO 17020. Where considered applicable by the TSR and the RM, calibration can be carried out by in house personnel against other certified equipment having a known valid relationship to recognised standards, (such certified equipment cannot be used for formal testing). Where no such standards exist, the basis for calibration shall be documented and recorded in the register by the RM. c) The RM or TSR shall ensure that: 1. all relevant functions of the test equipment are calibrated for the ranges or values in which the test equipment is to be used, based upon characteristic and accuracy requirements; 2. third party organisations providing the Calibration service supply a suitable Calibration Certificate for test equipment that has been calibrated and recorded as per the calibration review form on Management Database. 3. prior to use, all test equipment to be used is calibrated, where required; 4. access to adjustable devices which are fixed at the time of calibration are sealed or safeguarded. d) Test equipment exceeding any stated calibration due date must not be used for formal testing until it has been re-calibrated. e) An Equipment Calibration Schedule shall be established and maintained by the Branch Manager. The equipment calibration intervals shall be in accordance with the appropriate NATAfield application document and equipments manufacturers’ guideline. f) All equipment used for product acceptance shall be incorporated into the schedule. This includes the following examples: g)

The equipment calibration schedule shall list the following: -

Test beds and test trailers (vertical and horizontal); Rope measuring machines; Mechanical measuring equipment (Verniers, Micrometers, measuring tapes); Temperature and pressure gauges; NDT machines; Standard test blocks e.g Test Plates and Vernier Blocks and Any other test and measuring equipment.

equipment description; unique identification number; location; calibration interval date of calibration and; source.

Each item of equipment included on the schedule shall be uniquely identified. This identification number shall appear on the item of equipment and/or the container.

GSO/ITP/0411

Control of Inspection and Test Equipment

The location recorded on the schedule shall be that location within the warehouse where the item of equipment is normally used or stored. The calibration interval for each item of equipment shall be established. This shall be done after considering the following: -

manufacturer's calibration and service specifications; equipment usage and wear; equipment environment and stability.

The calibration interval may be adjusted to suit current conditions. They may be lengthened should equipment be used infrequently. They shall be shortened should any of the following conditions occur: -

5.4

Page 4 of 5

considerable increase in equipment use; considerable variation in measurement data; where environmental conditions become adverse.

Storage and Handling The test and measuring equipments shall be: 1. adequately stored and handled in accordance with manufacture’s recommendations, where applicable; 2. stored in such a manner that it meets any environment requirements; 3. storage location and methods are recorded in the asset register.

5.5 Calibration Record a) An equipment Calibration Record shall be maintained at the branch for each item of equipment on the schedule. The record shall indicate the calibration status of all items of equipment on the schedule. b) Where practicable, the calibration status of equipment shall be recorded on that piece of equipment by affixing a tag or label.Records shall be maintained to provide objective evidence that all inspection, measuring and test equipment is effectively controlled, calibrated and maintained. 5.6

New, Defective and Nonconforming Equipment

Equipment that is either defective, is out of calibration or does not pass a calibration check shall be deemed nonconforming, fitted with 'out of service' tag.The RM shall determine whether the equipment shall be repaired or replaced. Calibration criteria should be consulted by the TSR to determine the extent, if any, of required verification of previous test and inspection results and remedial action necessary.

5.7

Equipment Data Files

Equipment Data Files will be established to hold all manufacturer supplied data, operating manuals and calibration certificates for Company-owned inspection, measuring and test equipment. This information shall be filed by equipment brand or model name and shall include calibration criteria, national standard and/or Company instruction.

GSO/ITP/0411

Control of Inspection and Test Equipment

6.0

Documentation GSO/Calb/Rec/0411 GSO/CALB/Review form

GSO/ITP/0411

Page 5 of 5

Calibration Form Calibration Review Form

Revision: 4 Date: 080509 Page: 1 of 6 Compiled by: AJT Reviewed by: JP Authority: AJT IT-VI/O Visual Inspection of Lifting Appliances (OFFSHORE) using checklists

Bullivants Pty Ltd

TITLE:

1.Introduction The range of lifting appliances used in the offshore industry makes it difficult to specify all the requirements that need to be met for each individual design. It is therefore the responsibility of the appliance owner and the inspection service provider (Bullivants) to ensure that all appliances are fit for their intended purpose. 2.Purpose The purpose of this procedure is to ensure that the inspection of all lifting appliances presented to Bullivants is carried out in accordance with the requirements of the relevant standard and that the appropriate information is recorded and conveyed to the customer. (Note: This procedure does not contain all the provisions of the referenced standards. It is the responsibility of the user to make himself/herself aware of all the requirements, mandatory and advisory, of the selected standard). 3.Scope This procedure applies to the visual inspection of all lifting appliances presented to Bullivants for inspection. It does not apply to inspections which are carried out on new products immediately following manufacture, the results of which are recorded elsewhere. 4 References • • • • • • • • • • • • •

AS 1353.1 - Flat Synthetic Webbing Slings AS1353.2 - Flat synthetic webbing slings care and use AS1380 - Fibre rope slings AS1418.1 - Crane, hoist and winches – general requirements AS1418.2 - Cranes, serial hoist winches AS1418.17 - Crane, hoist and winches – Design & construction of workboxes AS1418.18 - Crane, hoist and winches – Crane runways & monorails AS1554 - welding steel structures AS 1666.1 - Wire Rope Slings Production Spec. AS1666.2 - Wire rope slings care and use AS2089 - Sheave blocks for lifting purposes AS2317 - Collared eyebolts AS2318 - Swivels for hoists

GSO / Procedure / Technical / 0509

Revision: 4 Date: 080509 Page: 2 of 6 Compiled by: AJT Reviewed by: JP Authority: AJT IT-VI/O Visual Inspection of Lifting Appliances (OFFSHORE) using checklists

Bullivants Pty Ltd

TITLE:

AS2319 - Rigging screws and turnbuckles AS2321 - Short link chain for lifting purposes AS2740 - Wedge type sockets AS2741 - Shackles AS3711.1 - Freight containers classifications, dimensions and ratings AS3775.1 - Chain Slings Grade T AS3775.2 - Grade T chain slings care and use AS3776 - Lifting components for grade T chain slings AS3777 - Shank hooks and large eye hooks AS4801 - Occupational health & safety management systems AS4100 - Steel Structures AS4991 - Lifting Devices AS 4497 - Synthetic Roundslings DNV 2.7-1 - Certification notes No. 2.7-1 for Offshore Containers DNV 2.7-2 - Offshore Service Containers DNV 2.7-3 - Portable Offshore Units EN12079 - Offshore Containers – Design, construction, testing, inspection & marking ISO9001 - Quality Management Systems – Requirements ISO9712 - Non-destructive testing - Qualification and certification of personnel ISO14001 - Environmental Management Systems – Specification with guidance for use ISO/IEC 17020 General criteria for the operation of various types of bodies performing inspection ISO/IEC 17020 NATA Application document ISO/IEC 17025 General requirements for the competence of testing and calibration laboratories ISO/IEC 17025 NATA Application Document Various AS/NZS ISO standards for lifting equipment Marine Orders Part 32 and 44 Local statutory requirements – Workcover, DME etc (changes depending on which state) Bullivants BPM Manual Bullivants Procedure – Test Certificates (IT-TC) Bullivants Procedure – NDT of Products (IT-NDT2) Bullivants Procedure – Visual Inspection of Lifting Appliances (IT-VI) Bullivants Procedure – Supplier & Product Evaluation Bullivants Work Instruction – Hire of Bullivants Equipment without an Operator Bullivants Procedure – Company Product Liability Statements Bullivants Procedure – Customer Supplied Product Bullivants Procedure – Inspection, Examination and Testing of Offshore Lifted Equipment & Associated lifting sets (IT-OLE) • Woodside Lifting Equipment Standard – W1000AG400

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

GSO / Procedure / Technical / 0509

Revision: 4 Date: 080509 Page: 3 of 6 Compiled by: AJT Reviewed by: JP Authority: AJT IT-VI/O Visual Inspection of Lifting Appliances (OFFSHORE) using checklists

Bullivants Pty Ltd

TITLE:

5 Definitions Inspection Examination and other such measures considered necessary to determine the conformity of a lifting appliance with specific requirements -or, on the basis of professional judgement, general requirements Lifting Appliance - Items (sometimes known as rigging, lifting devices or lifted equipment) including, but not restricted to, wire slings sets, chain sling sets, shackles, containers, baskets, beams, modules etc MSDB

Bullivants’ Management System Data Base

Service Agreement Checklist

Document detailing the terms, conditions and scope of work

Hard copy or electronic list of inspection criteria and results.

(There are many checklists in the MSDB but not all appliances are included in the scope of accreditation of the laboratory and therefore NATA endorsement can not be included on the certification for these items which precludes their use offshore)

6. Equipment The basic equipment required to conduct an inspection is noted in the body of the appropriate checklist. Items such as callipers, tape measures shall be uniquely identified and their use recorded. 7.Safety Work carried out at a customer’s location shall be subject to Bullivants’ safety requirements as detailed in the procedures nominated in section 4 supplemented by those of the customer. (On-site work shall not commence until a service agreement has been completed by the technician and signed by the customer’s representative. At this meeting take the opportunity to ensure that suitable means are available for lifting and supporting any appliance that requires an inspection of the underside. If they are not the work shall not proceed).

GSO / Procedure / Technical / 0509

Revision: 4 Date: 080509 Page: 4 of 6 Compiled by: AJT Reviewed by: JP Authority: AJT IT-VI/O Visual Inspection of Lifting Appliances (OFFSHORE) using checklists

Bullivants Pty Ltd

TITLE:

8.Personnel Personnel responsible for inspection shall have appropriate qualifications, training, experience and a satisfactory knowledge of the inspections to be carried out. They shall have the ability to make professional judgements as to conformity of an appliance with general requirements using inspection results and to report thereon. All training shall be recorded in Bullivants’ Skills & Competency database.

9. Procedure 9.1 Follow the inspection processes outlined in the selected standard, appropriate checklist and Bullivants’ procedure IT-LA, giving consideration to all of the following 9.2 The inspection criteria and methods covered by this procedure shall comply with those specified in one or more of the references listed in section 4. 9.3 The appropriate checklist for the appliance under review shall be selected from the MSDB and shall be used in conjunction with the manufacturer’s specifications as a guide to conducting the inspection and to form a record. (Note: Manufacturer’s specifications may not be available for older model appliances in which case the general requirements of the nominated standard shall apply). 9.4 If the appliance can not be inspected in accordance with any of the references in section 4 then appropriate drawings, engineering calculations, compliance certificate or similar sufficient to determine the correct acceptance criteria shall be supplied. 9.5 If the inspection of an appliance requires that it be dismantled and subsequently reassembled a proof load shall be applied and appropriate certification issued in accordance with Bullivants’ procedures IT-LA and IT-TC. (See ‘ Typical Report’ attached for mandatory information required on the report). If the appliance is included in the scope of accreditation for visual inspection of the branch then the certificate shall carry NATA endorsement. GSO / Procedure / Technical / 0509

Revision: 4 Date: 080509 Page: 5 of 6 Compiled by: AJT Reviewed by: JP Authority: AJT IT-VI/O Visual Inspection of Lifting Appliances (OFFSHORE) using checklists

Bullivants Pty Ltd

TITLE:

9.6 If there is a requirement to subcontract any part of the inspection the agreement of the customer shall be obtained before proceeding and shall be recorded on the test report (Note: All lifting appliances for offshore use shall be proof loaded prior to their first use. Documentary evidence of this requirement must be sighted before an endorsed certificate for inspection can be issued.) 10 .Attachments Typical Inspection Report Typical Inspection Record Typical Appliance Checklist

GSO / Procedure / Technical / 0509

Revision: 4 Date: 080509 Page: 6 of 6 Compiled by: AJT Reviewed by: JP Authority: AJT IT-VI/O Visual Inspection of Lifting Appliances (OFFSHORE) using checklists

Bullivants Pty Ltd

TITLE:

GSO / Procedure / Technical / 0509

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RESULTS: INSPECTION

CONFORMITY:

A.B.N:47087887072 WWW-b_ql.lyants=Eam wA6106 wA6106,POBox279Bentley PERTH welshpool Road 6l Kurnail 722999 1300 Sales: (08) 9350 6990 Facsimile: (08) 9i.22 Telephone: 9458 Bullivants | Page 619 of 692

VI-3 : CHAIN SLINGS Serviceman:

Customer:

Signature:

Customer Order No.:

Service Agreement No.:

Report No.:

Work covered by this instruction will only be carried out by: Technicians Technical Service Representatives (TSR) Senior Technical Services Representatives

Equipment Required: - Vernier Callipers - Ruler or Tape measure - Dividers * - Hammer & Centre punch * * Required for testing changes in gauge length before and post proof load

ADDITIONAL SAFETY EQUIPMENT REQUIRED:

HAND PROTECTION

Item Description:

Test Certificate No.:

Grade:

Proof Load:

Manufacturer:

Serial No.: Points to Cover

Cleaning

- If necessary, clean before inspecting

Chain link

Worn links

Multiple legs

- Inspect every chain link for wear, twisting, stretching, nicks or gouging - Heat effects - Measure to determine degree of wear, which should not exceed that allowed for by the manufacturer - usually 10% - Multiple legs are to be of equal length

Upper and lower terminal links, hooks, etc.

- Inspect for wear at their load bearing points and for any signs of distortion

Connecting devices

Chain links or fittings, load bearing pins

- Inspect for any signs of wear at load bearing point - Free movement - Any defects should be clearly marked to indicate rejection

Tag or label

Manufacture Measurement

Tolerance

Actual

Observation

Findings

Initials /Work Done

- Where a tag or label becomes detached, sling should be taken out of service - If sling is serviceable, replace tag and register

REP - Repair OK - Serviceable

Tolerance = Manufacturer Specification

040802

)

Working Load Limit (WLL):

Item of Chain Slings

Legend:

% OF WLL (Ref

US - Condemned CLN - Clean

LUB - Lubricate TST - Test

RLC - Replace N/A - Not applicable

Standards: AS3775.1 & AS3775.2 - Grade T Chain Slings AS3776 - Lifting components for Grade T Chain slings AS2321 - Short-Link chain for lifting purposes

Page 1 of 1

IT-VI - 3 Chain Slings.DOC

Bullivants | Page 620 of 692

Bullivants Pty Ltd

TITLE:

Revision: 6 Date: 2502016 Page: 1 of 8 Compiled by: AJT/JP Reviewed by: JP Authority: AJT

IT-OLE Inspection, Examination and Testing of Offshore Lifted Equipment and Associated lifting sets

1.Introduction The range of shapes, sizes and capacities of containers and other associated lifted equipment used in the offshore industry makes it difficult to specify all the requirements that need to be met for each individual design. It is therefore the responsibility of the equipment owner and the inspection/testing service provider (Bullivants) to ensure that all containers and other lifted equipment used in the offshore industry are fit for their intended purpose. The recommended knowledge and experience of personnel responsible for the inspection of containers, other lifted equipment and associated lifting sets is detailed in the attachments to this procedure. Offshore containers may be constructed with partly removable primary structure. Bolted or pinned connections will be specially considered with regard both to strength and securing . It is possible however that the internal procedures of an offshore company may not permit such containers to be used in areas where they have control .

2.Purpose The purpose of this procedure is to ensure that the inspection, testing and examination of all offshore containers, lifted equipment and associated lifting sets presented to Bullivants is carried out in accordance with the relevant standard. In addition, to ensure that if the required documentation is not available to support the integrity of the equipment it is not approved for offshore use. (Note: This procedure does not contain all the provisions of the referenced standards. It is the responsibility of the user to make himself/herself aware of all the requirements, mandatory and advisory of the selected standard). 3 Scope This procedure specifies the requirements for the periodic inspection and testing of offshore freight and service containers, other lifted equipment and their associated lifting sets by Bullivants’technicians.

Bullivants | Page 621 of 692

Bullivants Pty Ltd

TITLE:

Revision: 6 Date: 2502016 Page: 2 of 8 Compiled by: AJT/JP Reviewed by: JP Authority: AJT

IT-OLE Inspection, Examination and Testing of Offshore Lifted Equipment and Associated lifting sets

4.References 1) Marine Orders Part 32 (onshore, inshore and on-platform lifts only) 2) EN12079 Offshore Containers Lifting Sets- Inspection, Examination & testing 3) DNV 2.7-1 Offshore Containers 4) DNV 2.7-2 Offshore Service Container 5) DNV 2.7-3 Portable Offshore Unit 6) Bullivants’ procedure IT-WS Weighing of product 7) Bullivants’ procedure IT-LA Inspection and Testing-Lifting appliances 8) Bullivants’ procedure IT-NDT-2 NDT of Product 9) Bullivants procedure IT- VI/O Visual Inspection of Lifting Appliances (Offshore) using checklists 10) W1000AG4OO Standard Woodside Lifting Equipment (Note: Marine Orders Part 32 applies to the loading/unloading of a ship at a port. It does not apply to the loading/unloading of an offshore vessel at an offshore facility). 5.Symbols R The rating i.e.: the maximum gross mass of the container in kg T The tare mass i.e.: the weight of an empty container in kg 6.Definitions -

Offshore freight container- built for the transport of goods Offshore service container- built for special tasks(workshops, power plants etc) Onshore lift- a lift performed entirely on land On platform lift -a lift performed entirely onboard a fixed offshore platform Offshore lift- a lift performed to or from a vessel in an open sea environment. Inshore lift- a lift performed on/from a free floating or anchored vessel in a sheltered, still water environment Primary structure- load carrying and supporting frames and load carrying panels. MGM- maximum permissible combined weight of a container and its contents Responsible engineer- the engineer who is deemed accountable for design of the unit. Lifted equipment - the item to which the lifting set is attached includes items such as containers, lifting frames, baskets, skips skids, modules etc CCLE Certificate of Compliance for Lifted Equipment

Bullivants | Page 622 of 692

Bullivants Pty Ltd

TITLE:

Revision: 6 Date: 2502016 Page: 3 of 8 Compiled by: AJT/JP Reviewed by: JP Authority: AJT

IT-OLE Inspection, Examination and Testing of Offshore Lifted Equipment and Associated lifting sets

6.Definitions cont… -

CVI Certified Visual Inspection DVC Design Verification Certificate Service agreement - Document detailing the terms, conditions and scope of work Checklist - Hard copy or electronic list of inspection criteria and results Inspection - Examination and other such measures considered necessary to determine the conformity of a lifting equipment with specific requirements or on the basis of professional judgement – general requirements

7. Inspection equipment -

Suitable means of lifting and supporting the unit Steel hand pick or spike Load cell String line or laser leveller Wire brush Callipers, Tape measure Blank checklists and record formats

8.Safety Work carried out a customer’s location shall be subject to Bullivants’ safety requirements as detailed in the procedures or standards nominated in section 4 supplemented by those of the customer. (Note: On site work shall not commence until a service agreement has been completed by the technician and signed by the customer’s representative. At this meeting take the opportunity to ensure that suitable means are available for lifting and supporting the container for the purpose of inspecting the under-side. If they are not the work shall not proceed).

Bullivants | Page 623 of 692

Bullivants Pty Ltd

TITLE:

Revision: 6 Date: 2502016 Page: 4 of 8 Compiled by: AJT/JP Reviewed by: JP Authority: AJT

IT-OLE Inspection, Examination and Testing of Offshore Lifted Equipment and Associated lifting sets

9.Personnel Personnel with responsibilities in this procedure shall have appropriate qualifications, training, experience and a satisfactory knowledge of the work to be carried out. They shall have the ability to make professional judgements as to conformity of equipment with general requirements of inspection and test results and to report thereon. All training shall be recorded in Bullivants’ Skills & Competency database.

10.General requirements ( pre-examination)  

 

Equipment must be designed, fabricated, tested and certified for offshore conditions in accordance with one of the standards listed in section 4 or other relevant standard. Equipment must have the following current certification which may be included in one document - Certificate of Compliance or Conformity for Lifted Equipment (CCLE) certifying that the equipment has been designed and fabricated for offshore use - Design Verification certificate ( DVC) - Proof load test certificate - NDT (MPI or other) certificate - Visual inspection certificate (Note: For inspection / test frequency refer to the relevant standard. If the required documentation is not available then the equipment SHALL NOT BE APPROVED!) Each container shall have its own dedicated lifted set (wire rope or chain) fitted at a minimum included angle of 60 degrees ( 30 degrees Vertical ). Plates shall be of suitable size for the required information, should be of a durable material (eg marine grade aluminium) and securely fixed in a visible and protected location. (Note: Aluminium rivets have been found to be unsuitable as a fixing method in an offshore location and shall not be used. To avoid confusion the plate shall not show the date of the next inspection)

Bullivants | Page 624 of 692

Bullivants Pty Ltd

TITLE:

Revision: 6 Date: 2502016 Page: 5 of 8 Compiled by: AJT/JP Reviewed by: JP Authority: AJT

IT-OLE Inspection, Examination and Testing of Offshore Lifted Equipment and Associated lifting sets

General requirements ( pre-examination) cont…. Each of the above certificates shall reference the unique identification number of the unit and the lifting set. Lifted equipment shall be free of rust, dents, holes and loose attachments that may fall off during lifting. All lifting shackles shall be stamped with their grade and capacity and the pins must be secured with split pins . Only safety shackles shall be used for offshore and on-vessel lifts. Doors on closed containers shall be in good condition with hinges greased and an operational locking mechanism.

   

The following is STRICTLY NOT PERMITTED for offshore lifts-

Containers with twistlock corner fittings are not designed for offshore lifting operations and are not to be lifted offshore using slings and shackles attached to the twistlocks. These containers may only be lifted in an offshore environment when supported in a full load bearing, approved frame. Marinized (mechanically zinc coated) high strength chain Where a lifting set is replaced on a unit the new set shall be made to the original (or equivalent) specification, tested, certified and marked accordingly.

11. Procedure 11.1 Lifting Tests Lifting tests shall be carried out in accordance with the requirements of the relevant standard and Bullivants’ procedures IT-LA and IT-WS. Prior to carrying out the test requirements, the unit shall be visually checked in order to determine as far as possible that the pad eyes and general structure are free from wear, corrosion, holes or any other deleterious condition. If such a condition is identified the unit shall not be tested and the customer shall be informed. The container shall be loaded to give a total mass of 2,5R and lifted using 4 pad eyes. (The total mass may be obtained by putting in an internal mass of 2,5R-T).

Bullivants | Page 625 of 692

Bullivants Pty Ltd

TITLE:

Revision: 6 Date: 2502016 Page: 6 of 8 Compiled by: AJT/JP Reviewed by: JP Authority: AJT

IT-OLE Inspection, Examination and Testing of Offshore Lifted Equipment and Associated lifting sets

Lifting Tests cont…. The container shall then be loaded to give a total mass of 1,5R and lifted using 2 pad eyes. (The total mass may be obtained by putting in an internal mass of 1,5R-T). The test load shall normally be evenly distributed inside the container however if this is not possible some of it may be placed outside or under the container provided that this gives a loading on the structure similar to the distribution of the container loading in operating condition. ( All offshore freight containers must have the full test load evenly distributed over the floor area). (Note: Woodside Standard W1000AG400 (4.6.4.3) states“The use of tie down points in place of weights to generate internal loads is not permitted unless the Responsible Engineer has shown that the method adopted loads all structural components in the same manner as they would during lifting” Before the container is lifted two ‘pop’ marks are made near the bottom edge. A string line is used between these points to add a third indexing mark or reference point. The container shall be carefully lifted by a lifting set with an included angle equal to the design angle and shall be held clear of the ground for the time specified in the relevant standard. No deflections during testing shall be greater than 1/300th of the span of the member. After the container has been lowered it shall be checked visually for any permanent deformation by using the string line to check the alignment of the indexing ‘pop’ marks or with a laser leveller. The diagonal measurements are rechecked for any lateral distortion of the container or frame. The unit shall show no permanent deformation or damage after testing.

11.2 Non-destructive examination of welds. The NDE of welds on pad eyes (lifting lugs) shall be carried out in accordance with the requirements of the relevant standard and Bullivants’ procedure IT-NDT-2.

Bullivants | Page 626 of 692

Bullivants Pty Ltd

TITLE:

Revision: 6 Date: 2502016 Page: 7 of 8 Compiled by: AJT/JP Reviewed by: JP Authority: AJT

IT-OLE Inspection, Examination and Testing of Offshore Lifted Equipment and Associated lifting sets

11.3 Visual Inspection Visual inspection shall be carried out in accordance with the requirements of the relevant standard, the appropriate checklist and Bullivants’ procedure IT-VI/O. The visual inspection of a container shall be of the exterior and interior without cargo to ensure that the container is fit for its intended use. All load bearing parts, especially the base structure, shall be inspected. For containers with fixed equipment the technician shall determine whether access to load bearing parts is adequate. The inspection shall be carried out in a situation providing sufficient lighting and other facilities necessary to allow it to be carried out safely and effectively. (The technician shall ensure that suitable means for lifting and supporting the equipment has been provided for the purpose of inspecting the under-side. If they are not the inspection shall be terminated). NOTE: If a customer requires a different specification that is not on the CCLE then the customer must be advised that this may not comply to DNV. It may be a different standard. This would be completed in writing 11.4 Lifting Sets – Examination and Test Lifting sets shall be periodically inspected, examined, tested and marked in accordance with the requirements of the relevant standard and Bullivants’ procedures IT-LA and IT-VI/O. 12. Attachments A. Recommended knowledge and experience of staff responsible for inspection of offshore containers B. Recommended knowledge and experience of staff responsible for inspection Of lifting sets intended for use with offshore containers.

Bullivants | Page 627 of 692

Bullivants Pty Ltd

TITLE:

Revision: 6 Date: 2502016 Page: 8 of 8 Compiled by: AJT/JP Reviewed by: JP Authority: AJT

IT-OLE Inspection, Examination and Testing of Offshore Lifted Equipment and Associated lifting sets

I …………………………………hereby testify that I have read and understood

this procedure dated …………...….and I…………………………... do hereby on

the behalf of Bullivants Pty Ltd, testify that I have tested the above

signatory on this day………………..and the signatory has satisfactorily

understood and met the requirements of this procedure.

Bullivants | Page 628 of 692

Bullivants Pty Ltd

Revision:

1019

REFERENCE: GSO/IT/SHW

Page: Authority:

1 of 6 AJT

SERVICE AND TEST OF MANUAL CHAINBLOCK, LEVERBLOCK, ELECTRIC CHAIN HOISTS AND WIRE ROPE HOISTS

1. SCOPE To establish and maintain a system to the overhaul and test of manual chain blocks, lever blocks and electric chain and wire rope hoists. 2. REFERENCES •

ISO9001 - Quality Management Systems – Requirements

•

AS1418.2 – Serial Hoists and Winches

•

IT-LA – Testing Lifting Appliances

•

IT-TC – Test Certificates

•

Visual Inspection checklists

•

Manufacturers hand books and parts lists EQUIPMENT

• • • •

Vertical or horizontal testing facility’s Load Cell.- enclosed on test unit or mobile units Operators manual General tools for mechanical service works

3. DEFINITIONS •

Serial Hoists and Winches as described in AS 2549 ( Cranes – Glossary of terms)

4. SAFETY •

Ensure all the correct PPE is worn by service and testing personnel

•

Ensure testing staff are NOT standing inline with handles of lever blocks and the chain block hand chains in case of slippage during the process of operating the serial hoist

5. RESPONSIBILITIES •

Work covered in this procedure shall be carried out by company Technical Service Officers , Licensed Electrical Tradesperson ( if applicable) or Technicians as deemed competent by the branch manager

6. PROCEDURE •

To service the hoists or winches undertake the following steps: -

completely strip hoist (excluding electrics);

clean all components;

check brake lining thickness for wear for conformity to manufacturer's specification;

remove covers and check electrical operation ( if applicable) check motor winding - undertake Megger test ( if applicable)

Bullivants | Page 629 of 692

Bullivants Pty Ltd

Revision:

1019

REFERENCE: GSO/IT/SHW

Page: Authority:

2 of 6 AJT

SERVICE AND TEST OF MANUAL CHAINBLOCK, LEVERBLOCK, ELECTRIC CHAIN HOISTS AND WIRE ROPE HOISTS

•

check chain/rope for wear/corrosion - refer visual inspection of rope (Visual Inspection of Rigging Products using Checklists);

visual inspection of chains to ensure the wear is not greater than manufacturer's tolerance;

visual inspection of hooks for conformance to requirement;

check pocket wheel for wear (chain hoist);

check sheaves for correct profile and smoothness (wire rope hoist);

check rope drum for correct profile and smoothness (wire rope hoist);

check rope guide for wear and sloppiness (wire rope hoist);

replace gasket ( if required)

reassemble all components;

replace lubricants to manufacturer's specification.

Acceptance prior to TEST

Acceptable if wear is not greater than manufacturers tolerances , no sign of distortion or permanent set and no evidence that worn parts have been replaced previously.

Testing Process – it is mandatory that all units they have been repaired , serviced or rechained shall be proof loaded in accordance with the relevent Australian Standards Our preferred method is to test on horizontal units as shown below . • • • •

Commence operation by first checking ram operation, forward and backwards, 20 -30mm either direction, using the external levers or refer to the operating procedure for the test bed being used. Adjust pressure relief valve out until the hydraulic system is at the lowest pressure. Position directional valve and extend the hydraulic ram about 300 mm and connect equipment to be tested. Ensure the protective covers are lowered or fitted where practicable before commencing load tests.

Bullivants | Page 630 of 692

Bullivants Pty Ltd

Revision:

1019

REFERENCE: GSO/IT/SHW

Page: Authority:

3 of 6 AJT

SERVICE AND TEST OF MANUAL CHAINBLOCK, LEVERBLOCK, ELECTRIC CHAIN HOISTS AND WIRE ROPE HOISTS

• •

Again ,ensure all non-BULLIVANTS personnel are removed from the area or behind the test screen/s Reposition directional valve to retract ram and adjust the pressure valve until the required PROOF force is obtained. (see example below for serial hoists, check your test methods as per your standards booklets or other test specification provided with the sales order) Testing of chain blocks is conducted in accordance with AS 1418 - 1997 Cranes (Including hoists and winches) part 2: Serial hoists and winches (under clauses relating to proof testing). NB: This standard requires the block to be operated in both hoisting and lowering through a sufficient distance to ensure the slowest moving part rotates through one revolution. ( see attached NATA regulations , page 41 for allowable variances whilst proof loading serial hoists – which are minus 5% to plus 20% of the applicable proof load)

Bullivants | Page 631 of 692

Bullivants Pty Ltd

Revision:

1019

REFERENCE: GSO/IT/SHW

Page: Authority:

4 of 6 AJT

SERVICE AND TEST OF MANUAL CHAINBLOCK, LEVERBLOCK, ELECTRIC CHAIN HOISTS AND WIRE ROPE HOISTS

When the operational testing is completed reposition the directional valve to extend the hydraulic ram to enable the removal of the equipment. Ensure the pressure relief valve is FULLY OPEN, so when the next test commences there is residual pressure that may be higher than the previous test. •

Or/ if testing in a vertical unit , please follow method below , unless your branch has a specific procedure for your machine. 1. Visually inspect serial hoist to determine if repairs are required before proof loading 2. Install serial hoist to vertical test tower upper connection: refer vertical tower procedure 3. Operate hoists in all modes up/down/neutral before attaching to cylinder clevis 4. If operation appears to be normal connect lower hook to cylinder clevis 5. Ensure that serial hoist is switched to “raise” 6. Vacate testing area and close door 7. Turn on testing machine hydraulic unit 8. Operate vernier control valve to minimum setting (anti clockwise) 9. Select ‘down’ with direction lever 10. Load will be gradually applied to the serial hoist automatically 11. Watch serial hoist to determine if slip occurs during load application 12. Slowly increase load to maximum rated capacity of the serial hoist 13. Watch serial hoist for any indications of slip during the load application. 14. When you are satisfied that the brake system is holding or a specific time period has elapsed 15. Reduce the load on the serial hoist and return lever to off position 16. Enter the cage and switch serial hoist to lower 17. Repeat the test for this mode of operation to the rated capacity. 18. When you are satisfied that the braking system is functioning 19. Return lever to off position and reduce applied load to test machine minimum setting 20. Switch serial hoist to raise 21. Operate lever to down and apply minimum vernier setting or 10% of serial hoist MRC 22. Operate the serial hoist in raise and lower to check functions 23. Increase load to 80% MRC and operate serial hoist ensuring that the slowest moving part rotates 360 degrees this would usually be generally load chain pocket wheel (safety) ensure sufficient clearance to object within and the guarding of the cage. Use your body weight to operate the device. Ensure that parts of your body cannot come into contact with ? 24. When you are satisfied that serial hoist operates correctly, reduce applied load and select the down function and ensure that the unit is ‘cracked’ to allow normal operation. 25. Disconnect serial hoist from cylinder clevis 26. Select neutral position and check for correct operation refer specific user manual 27. Remove serial hoist from upper link 28. Attach proof load id tag and complete test record.

Bullivants | Page 632 of 692

Bullivants Pty Ltd

Revision:

1019

REFERENCE: GSO/IT/SHW

Page: Authority:

5 of 6 AJT

SERVICE AND TEST OF MANUAL CHAINBLOCK, LEVERBLOCK, ELECTRIC CHAIN HOISTS AND WIRE ROPE HOISTS clearance to object within and the guarding of the cage. Use your body weight to operate the device. Ensure that parts of your body cannot come into contact with ? 24. When you are satisfied that serial hoist operates correctly, reduce applied load and select the down function and ensure that the unit is ‘cracked’ to allow normal operation. 25. Disconnect serial hoist from cylinder clevis 26. Select neutral position and check for correct operation refer specific user manual 27. Remove serial hoist from upper link 28. Attach proof load id tag and complete test record.

GSO / Procedure / Technical/ Service & Testing of Manual Chain blocks , Leverblocks , Electric chain or Wire rope Hoists 1019 Confidential © Copyright Bullivants | Page 633 of 692

Bullivants Pty Ltd

Revision:

1019

REFERENCE: GSO/IT/SHW

Page: Authority:

6 of 6 AJT

SERVICE AND TEST OF MANUAL CHAINBLOCK, LEVERBLOCK, ELECTRIC CHAIN HOISTS AND WIRE ROPE HOISTS



Certificate

Issue the test certificate in accordance with the Bullivants Test certificate procedure , IT_TC , and the applicable Australian Standard and or NATA requirement.

GSO / Procedure / Technical/ Service & Testing of Manual Chain blocks , Leverblocks , Electric chain or Wire rope Hoists 1019 Confidential © Copyright Bullivants | Page 634 of 692

Fibre Core

0919 8 of 23 AJT/GD PO‐FV‐SC

Revision:: Page: Authority: Reference:

Title: Press Operation –Ferrule Verification & Selection charts

Pressing Chart 1 – Aluminium & Copper Ferrules Nominal Rope Diameter (mm)

Limits of Actual Rope Diameter (mm) From (mm)

To (mm)

Case 1 Single layer round strand rope with FC and Cable laid ropes. Fill Factor min 0.36 mm

C ≥ 0,283

After Pressing Ferrule Dimensions

EN Ferrule Diameter

Approx Press Load (Tonnes)

EN Ferrule Length

Use Ferrule Code (EN)

Use Die Code (EN)

Max (mm)

Min (mm)

Max (mm)

Min (mm)

2.5

2.7

2.5

5.2

2.8

3.2

3.0

6.2

3.5

3.3

3.7

3.5

7.2

3.8

4.3

4.0

8.2

4.5

4.4

4.8

4.5

9.2

4.9

5.4

5.0

10.2

5.5 6.0

5.9 6.4

6.0

12.4

6.5

6.9

6.5

13.4

7.0

7.4

7.0

14.4

7.5 8.0 8.5 9.0 9.6 10.0 10.6 11.0 11.7 12.0 12.7 13.0 13.8 14.0 14.8 16.0

7.9 8.4 8.9 9.5 9.9 10.5 10.9 11.6 11.9 12.6 12.9 13.7 13.9 14.7 15.9 16.8

8.0

16.4

9.0

18.4

10.0

20.5

11.0

22.5

12.0

24.5

13.0

26.5

14.0

28.7

16.0

32.7

110

8 9 10 11 12 13 14 16 NB. * Ŧ †

Fill factor (f) represents the ratio between the total metallic area circumscribed by the nominal diameter. Area factor (C) represents the factor derived from the fill factor (f) and is used in the calculation to determine the nominal cross-sectional area of a rope. Tensile grade of the wire is not to exceed 2070 Mpa

GSO / PO-FV-SC / 0220

Bullivants | Page 635 of 692

Fibre Core

0919 9 of 23 AJT/GD PO‐FV‐SC

Revision:: Page: Authority: Reference:

Title: Press Operation –Ferrule Verification & Selection charts

Pressing Chart 1 – Aluminum & Copper Ferrules Nominal Rope Diameter (mm)

Limits of Actual Rope Diameter (mm) From (mm)

18 20 22 24 26 28 30 32 34 36 38 40 44 48 52 56 60 NB. * Ŧ †

To (mm)

16.9 18.0 19.0 20.0 21.1 22.0 23.2 24.0 25.3 26.0 27.4 28.0 29.5 30.0 31.6 32.0 33.7 34.0 35.8 36.0 37.9 38.0

17.9 18.9 19.9 21.0 21.9 23.1 23.9 25.2 27.9 27.3 27.9 29.4 29.9 31.5 31.9 33.6 33.9 35.7 35.9 37.8 37.9 39.9

40.0

42.0

42.1 44.0 46.3 48.0 50.5 52.0 54.7 56.0 58.9 60.00

43.9 46.2 47.9 50.4 51.9 54.6 55.9 58.8 59.9 63.00

Case 1 Single layer round strand rope with FC and Cable laid ropes. Fill Factor min 0.36 mm

C ≥ 0,283

Approx Press Load (Tonnes)

After Pressing Ferrule Dimensions

EN Ferrule Diameter

EN Ferrule Length

Use Ferrule Code (EN)

Use Die Code (EN)

Max (mm)

Min (mm)

Max (mm)

Min (mm)

18.0

36.9

130

20.0

40.9

180

22.0

44.9

108

230

24.0

49.1

117

108

280

26.0

53.1

126

117

330

28.0

57.1

135

126

380

30.0

61.4

144

135

430

32.0

65.4

153

144

480

34.0

69.4

162

153

535

36.0

73.6

171

162

590

38.0

77.6

180

171

640

40.0

81.6

190

180

700

44.0

89.9

208

198

900

48.0

97.9

234

216

1000

52.0

106.1

104

248

234

1000+

114.3

112

270

252

1000+

60.00

122.4

120

290

270

1000+

GSO / PO-FV-SC / 0220

Bullivants | Page 636 of 692

Wire Rope Core

Revision:: Page: Authority: Reference:

Title: Press Operation –Ferrule Verification & Selection charts

0919 10 of 23 AJT/GD PO‐FV‐SC

Pressing Chart 2 – Aluminum & Copper Ferrules Nominal Rope Diameter (mm)

Limits of Actual Rope Diameter (mm)

From (mm)

To (mm)

Case 2 Single layer round strand rope with IWRC and rotation-resistant ropes. Fill Factor max 0.62 mm

C ≤ 0,487

Approx Press Load (Tonnes)

After Pressing Ferrule Dimensions

EN Ferrule Diameter

EN Ferrule Length

Use Ferrule Code (EN)

Use Die Code (EN)

Max (mm)

Min (mm)

Max (mm)

Min (mm)

2.5

2.7

6.2

2.8

3.2

3.5

7.2

3.5

3.3

3.7

8.2

3.8

4.3

4.5

9.2

4.5

4.4

4.8

10.2

4.9

5.4

12.4

5.5 6.0

5.9 6.4

6.5

13.4

6.5

6.9

14.4

7.0

7.4

16.4

7.5 8.0 8.5 9.0 9.6 10.0 10.6 11.0 11.7 12.0 12.7 13.0 13.8 14.0

7.9 8.4 8.9 9.5 9.9 10.5 10.9 11.6 11.9 12.6 12.9 13.7 13.9 14.7

18.4

20.5

22.5

24.5

26.5

28.7

32.7

110

8 9 10 11 12 13 14 NB. * Ŧ †

Fill factor (f) represents the ratio betweent the total metalic area circumscribed by the nominal diameter. Area factor (C) represents the factor derived from the fill factor (f) and is used in the calculation to deterime the nominal cross-sectional area of a rope. Tensile grade of the wire is not to exceed 2160 Mpa

GSO / PO-FV-SC / 0220

Bullivants | Page 637 of 692

Wire Rope Core

Revision:: Page: Authority: Reference:

Title: Press Operation –Ferrule Verification & Selection charts

0919 11 of 23 AJT/GD PO‐FV‐SC

Pressing Chart 2 – Aluminum & Copper Ferrules Nominal Rope Diameter (mm)

Limits of Actual Rope Diameter (mm)

From (mm)

16 18 20 22 24 26 28 30 32 34 36 38 40 44 48 52 56 60

To (mm)

14.8 16.0 16.9 18.0 19.0 20.0 21.1 22.0 23.2 24.0 25.3 26.0 27.4 28.0 29.5 30.0 31.6 32.0 33.7 34.0 35.8 36.0 37.9

15.9 16.8 17.9 18.9 19.9 21.0 21.9 23.1 23.9 25.2 25.9 27.3 27.9 29.4 29.9 31.5 31.9 33.6 33.9 35.7 35.9 37.8 37.9

38.0

39.9

40.0

42.0

42.1

43.9

44.0 46.3 48.0 50.5 52.0 54.7 56.0 58.9 60

46.2 47.9 50.4 51.9 54.6 55.9 58.8 59.9 63

GSO / PO-FV-SC / 0220

Case 2 Single layer round strand rope with IWRC and rotation-resistant ropes. Fill Factor max 0.62 mm

C ≤ 0,487

Approx Press Load (Tonnes)

After Pressing Ferrule Dimensions

EN Ferrule Diameter

EN Ferrule Length

Use Ferrule Code (EN)

Use Die Code (EN)

Max (mm)

Min (mm)

Max (mm)

Min (mm)

36.9

130

40.9

180

44.9

108

230

49.1

117

108

280

53.1

126

117

330

57.1

135

126

380

61.4

144

135

430

65.4

153

144

480

69.4

162

153

535

73.6

171

162

590

77.6

180

171

640

81.6

190

180

700

89.9

208

198

900

97.9

234

216

1000

106.1

104

248

234

1000+

114.3

112

270

252

1000+

122.4

120

290

270

1000+

¯ ¯

Bullivants | Page 638 of 692

High Fill Factor Ropes NR 0919 12 of 23 AJT/GD PO‐FV‐SC

Revision:: Page: Authority: Reference:

Title: Press Operation –Ferrule Verification & Selection charts

Pressing Chart 3 – Aluminum & Copper Ferrules Nominal Rope Diameter (mm)

Limits of Actual Rope Diameter (mm)

From (mm)

To (mm)

Case 3 Single layer round strand ropes with IWRC, rotation-resistant ropes and parallel-closed ropes Fill Factor 0.62 - 0.78mm

0,487< C ≤ 0,613

Approx Press Load (Tonnes)

After Pressing Ferrule Dimensions

EN Ferrule Diameter

EN Ferrule Length

Use Ferrule Code (EN)

Use Die Code (EN)

Max (mm)

Min (mm)

Max (mm)

Min (mm)

2.5

2.7

2.8

3.2

3.5

3.3

3.7

3.8

4.3

4.5

4.4

4.8

4.9

5.4

5.5 6.0

5.9 6.4

¯ 7

¯ 14.4

¯ 14

¯ 36

¯ 32

¯ 30

6.5

6.9

16.4

7.0

7.4

18.4

7.5 8.0 8.5 9.0 9.6 10.0 10.6 11.0 11.7 12.0 12.7 13.0 13.8 14.0 14.8 16.0

7.9 8.4 8.9 9.5 9.9 10.5 10.9 11.6 11.9 12.6 12.9 13.7 13.9 14.7 15.9 16.8

9 10 10 11 11 12 12 13 13 14 14 16 16 18 18 20

18.4 20.5 20.5 22.5 22.5 24.5 24.5 26.5 26.5 28.7 28.7 32.7 32.7 36.9 36.9 40.9

18 20 20 22 22 24 24 26 26 28 28 32 32 36 36 40

45 50 50 54 54 59 59 63 63 72 72 81 81 90 90 99

40 45 45 50 50 54 54 59 59 63 63 72 72 81 81 90

40 45 45 55 55 60 60 70 70 90 90 110 110 130 130 180

8 9 10 11 12 13 14 16 NB. * Ŧ †

GSO / PO-FV-SC / 0220

Bullivants | Page 639 of 692

High Fill Factor Ropes NR 0919 13 of 23 AJT/GD PO‐FV‐SC

Revision:: Page: Authority: Reference:

Title: Press Operation –Ferrule Verification & Selection charts

Pressing Chart 3 – Aluminum & Copper Ferrules Nominal Rope Diameter (mm)

Limits of Actual Rope Diameter (mm)

From (mm)

18 20 22 24 26 28 30 32 34 36 38 40 44 48 52 56 60 NB. * Ŧ †

To (mm)

Case 3 Single layer round strand ropes with IWRC, rotation-resistant ropes and parallel-closed ropes Fill Factor 0.62 - 0.78mm

0,487< C ≤ 0,613 Use Ferrule Code (EN)

Use Die Code (EN)

Approx Press Load (Tonnes)

After Pressing Ferrule Dimensions

EN Ferrule Diameter

EN Ferrule Length

Min (mm) 40 44 44 48 48 52 52 56 56 60 60 64 64 68 68 72 72 76 76 80 80 88

Max (mm) 99 108 108 117 117 126 126 135 135 144 144 153 153 162 162 171 171 180 180 190 190 208

Min (mm) 90 99 99 108 108 117 117 126 126 135 135 144 144 153 153 162 162 171 171 180 180 198

180 230 230 280 280 330 330 380 380 430 430 480 480 535 535 590 590 640 640 700 700 900

16.9 18.0 19.0 20.0 21.1 22.0 23.2 24.0 25.3 26.0 27.4 28.0 29.5 30.0 31.6 32.0 33.7 34.0 35.8 36.0 37.9 38.0

17.9 18.9 19.9 21.0 21.9 23.1 23.9 25.2 25.9 27.3 27.9 29.4 29.9 31.5 31.9 33.6 33.9 35.7 35.9 37.8 37.9 39.9

20 22 22 24 24 26 26 28 28 30 30 32 32 34 34 36 36 38 38 40 40 44

Max (mm) 40.9 44.9 44.9 49.1 49.1 53.1 53.1 57.1 57.1 61.4 61.4 65.4 65.4 69.4 69.4 73.6 73.6 77.6 77.6 81.6 81.6 89.9

40.0

42.0

97.9

234

216

1000

42.1 44.0 46.3 48.0 50.5 52.0 54.7 56.0 58.9 60.00

43.9 46.2 47.9 50.4 51.9 54.6 55.9 58.8 59.9 63.00

48 52 52 56 56 60 ¯ ¯ ¯ ¯

97.9 106.1 106.1 114.3 114.3 122.4 ¯ ¯ ¯ ¯

96 104 104 112 112 120 ¯ ¯ ¯ ¯

234 248 248 270 270 290 ¯ ¯ ¯ ¯

216 234 234 252 252 270 ¯ ¯ ¯ ¯

1000 1000+ 1000+ 1000+ 1000+ 1000+ ¯ ¯ ¯ ¯

GSO / PO-FV-SC / 0220

Bullivants | Page 640 of 692

Revision:: Page: Authority: Reference:

Title: Press Operation –Ferrule Verification & Selection charts

0919 14 of 23 AJT/GD PO‐FV‐SC

Pressing Chart 4 – Aluminum & Copper Ferrules Nominal Rope Diameter (mm)

Limits of Actual Rope Diameter (mm)

Approx Press Load (Tonnes)

After Pressing Ferrule Dimensions

Case 4 Spiral strand 2 Ferrules

From (mm)

To (mm)

Fill Factor min 0.78 mm

C ≥ 0,613

EN Ferrule Diameter

EN Ferrule Length

Use Ferrule Code (EN)

Use Die Code (EN)

Max (mm)

Min (mm)

Max (mm)

Min (mm)

2.5

2.7

2.8

3.2

3.5

3.3

3.7

3.8

4.3

10.2

4.5

4.4

4.8

12.4

4.9

5.4

6.5

13.4

5.5 6.0

5.9 6.4

14.4

6.5

6.9

16.4

7.0

7.4

18.4

7.5 8.0 8.5 9.0 9.6 10.0 10.6 11.0 11.7 12.0 12.7 13.0 13.8 14.0 14.8 16.0

7.9 8.4 8.9 9.5 9.9 10.5 10.9 11.6 11.9 12.6 12.9 13.7 13.9 14.7 15.9 16.8

20.5

22.5

24.5

26.5

28.7

32.7

110

36.9

130

40.9

180

8 9 10 11 12 13 14 16 NB. * Ŧ

GSO / PO-FV-SC / 0220

Bullivants | Page 641 of 692

Revision:: Page: Authority: Reference:

Title: Press Operation –Ferrule Verification & Selection charts

0919 15 of 23 AJT/GD PO‐FV‐SC

Pressing Chart 4 – Aluminum & Copper Ferrules Nominal Rope Diameter (mm)

Limits of Actual Rope Diameter (mm)

2 Ferrules From (mm)

18 20 22 24 26 28 30 32 34 36 38 40 44 48 52 56 60 NB. * Ŧ

Approx Press Load (Tonnes)

After Pressing Ferrule Dimensions

Case 4 Spiral strand

To (mm)

Fill Factor min 0.78 mm

C ≥ 0,613

EN Ferrule Diameter

EN Ferrule Length

Use Ferrule Code (EN)

Use Die Code (EN)

Max (mm)

Min (mm)

Max (mm)

Min (mm)

44.9

108

230

49.1

117

108

280

53.1

126

117

330

57.1

135

126

380

61.4

144

135

430

65.4

153

144

480

69.4

162

153

535

73.6

171

162

590

77.6

180

171

640

81.6

190

180

700

89.9

208

198

900

16.9 18.0 19.0 20.0 21.1 22.0 23.2 24.0 25.3 26.0 27.4 28.0 29.5 30.0 31.6 32.0 33.7 34.0 35.8 36.0 37.9 38.0

17.9 18.9 19.9 21.0 21.9 23.1 23.9 25.2 27.9 27.3 27.9 29.4 29.9 31.5 31.9 33.6 33.9 35.7 35.9 37.8 37.9 39.9

40.0

42.0

97.9

234

216

1000

42.1 44.0 46.3 48.0 50.5 52.0 54.7 56.0 58.9 60.00

43.9 46.2 47.9 50.4 51.9 54.6 55.9 58.8 59.9 63.00

48 52 52 56

97.9 106.1 106.2 114.3

96 104 104 112

234 248 248 270

216 234 234 252

1000 1000+ 1000+ 1000+

122.4

120

290

270

1000+

GSO / PO-FV-SC / 0220

Bullivants | Page 642 of 692

Revision:: Page: Authority: Reference:

Title: Press Operation –Ferrule Verification & Selection charts

0919 16 of 23 AJT/GD PO‐FV‐SC

Pressing chart 5 - Fill Factors & "C" Factors Brand

Casar Casar Casar Casar Casar Casar Casar Casar Casar Casar Casar Casar Casar Casar Casar

Type / Construction

Starlift Eurolift Powerlift Powerplast Turboplast Superplast Stratolift Turbolift Superlift Alphalift Betalift Unilift Megalift Multilift Quadrolift Brand

Trefil Trefil Trefil Trefil Trefil Trefil Trefil Trefil Trefil Trefil Trefil Trefil Trefil Trefil

Type / Construction

Notor / 28x7 Notor / 32x7 Notor / 35x7 Notor / 35x17 Notor / 35x26 NRHD 24 / 24x7 NRHD 24 / 24x17 NRHD 24 / 24x17C NRHD 24 / 24x21 NRHD 24 / 24x26 HP 8P / 8x36 HP 8P / 8x47 Complast 9 Complast 9 SR Brand

BHP - One Steel

GSO / PO-FV-SC / 0220

Type / Construction Compak / 34Wx7

Fill Factor 0.650 0.745 0.745 0.720 0.655 0.690 0.665 0.735 0.755 0.650 0.755 0.660 0.655 0.663 0.680 Fill Factor 0.690 0.690 0.690 0.689 0.693 0.625 0.625 0.662 0.643 0.646 0.628 0.628 0.673 0.673 Fill Factor 0.700

"C" Factor

0.510 0.585 0.585 0.565 0.514 0.542 0.522 0.577 0.593 0.510 0.593 0.518 0.514 0.521 0.534 "C" Factor

0.542 0.542 0.542 0.541 0.544 0.491 0.491 0.520 0.505 0.507 0.493 0.493 0.528 0.528 "C" Factor 0.550

Bullivants | Page 643 of 692

Revision:: Page: Authority: Reference:

Title: Press Operation –Ferrule Verification & Selection charts

0919 17 of 23 AJT/GD PO‐FV‐SC

Pressing chart 5 - Fill Factors & "C" Factors Brand

Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin Usher Martin

Type / Construction

Powerform 35 / 35xK7 Powerform 35 / 35xK19S Powerform 35P / 35xK7 Powerform 35P / 35xK19S Hyflex 35 / 35x7 Powerform 18 / 18xK7 Hyflex 18 / 18x7 Powerform 6 / 6xK36SW Powerform 6 / 6xK41SW Powerform 8P / 8PIxK26SW Hyflex 8P / 8PIxK26SW Powerform 8PC / 8xK7-CWRP Powerform 8PC / 8xK26SW-CWRP Hyflex 4 / 4x39-CFS Hyflex 6x36 / 6x36-CWR Hyflex 6x19 / 6x19S-CWR Hyflex 6x19 / 6x19W-CWR Hyflex 6x19 / 6x25F-CWR Hyflex 6x16 / 6x26SW-CWR

GSO / PO-FV-SC / 0220

Fill Factor 0.745 0.745 0.745 0.745 0.635 0.663 0.615 0.675 0.675 0.655 0.598 0.705 0.705 0.508 0.609 0.596 0.596 0.596 0.596

"C" Factor

0.585 0.585 0.585 0.585 0.499 0.521 0.483 0.530 0.530 0.514 0.470 0.554 0.554 0.399 0.478 0.468 0.468 0.468 0.468

Bullivants | Page 644 of 692

Revision:: Page: Authority: Reference:

Title: Press Operation –Ferrule Verification & Selection charts

0919 18 of 23 AJT/GD PO‐FV‐SC

Pressing Chart 6 – Aluminum & Copper Ferrules for Superflex Ropes Cable Size Two - 5

Nominal Rope Diameter (mm)

Use DIN Ferrule Code *Refer to

Use DIN Die Code

Approx Press Load (Tonnes)

notes

Two - 5 Three - 0 Three - 5 Four - 0 Four - 5 Five - 0 Six - 5 Eight - 0 Ten - 0

10 12 14 16 18 20 26 32 40

45 60 90 110 130 180 330 480 700

After Pressing Ferrule Dimensions DIN Ferrule DIN Ferrule Length Diameter Max (mm)

Min (mm)

Max (mm)

Min (mm) **

20.50 24.50 28.70 32.70 36.80 40.80 53.10 65.40 81.60

20.00 24.00 28.00 32.00 36.00 40.00 52.00 64.00 80.00

50 59 72 81 90 99 126 153 192

45 54 63 72 81 90 117 144 180

Notes: * When manufacturing Superflex rope into assemblies and the Superflex Rope cannot be fitted into the nominated Din ferrule - please refer to Bullivants Technical Department. ** Andromeda Cables do not specify after swaging ferrule lengths for verification when manufacturing Superflex Slings and Superflex Pole Strops. Information from the Din standard has been included for verification requirements. The information note above, for the manufacturing of Superflex Sling/Strop is sourced from Andromeda Cables. The correct Din Ferrule size to for manufacturing of Superflex assemblies was referenced from Andromeda Technical Brochure 052-10, which includes technical sheets 052-11 and 052-12 and technical sheet SF101-04.

GSO / PO-FV-SC / 0220

Bullivants | Page 645 of 692

Title: Press Operation –Ferrule Verification & Selection charts

Revision:: Page: Authority: Reference:

0919 19 of 23 AJT/GD PO‐FV‐SC

Pressing Chart 7 – Australoc Ferrules Rope Diameter (mm) 6 8 9.5 11 13 14 16 19 22 26 28 32 36 38 44 52 56 64 70 75

Nominal Rope Diameter (inches) 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 3

GSO / PO-FV-SC / 0220

Bullivants Product Code

Crosby Part No.

WFES-063-TP-C-S505 WFES-079-TP-C-S505 WFES-095-TP-C-S505 WFES-111-TP-C-S505 WFES-127-TP-C-S505 WFES-142-TP-C-S505 WFES-158-TP-C-S505 WFES-190-TP-C-S505 WFES-222-TP-C-S505 WFES-254-TP-C-S505 WFES-285-TP-C-S505 WFES-317-TP-C-S505 WFES-349-TP-C-S505 WFES-381-TP-C-S505 WFES-444-TP-C-S505 WFES-508-TP-C-S505 WFES-571-TP-C-S505 WFES-635-TP-C-S505 WFES-698-TP-C-S505 WFES-762-TP-C-S505

1041063 1041090 1041107 1041125 1041143 1041161 1041189 1041205 1041223 1041241 1041269 1041287 1041303 1041321 1041349 1041369 1041385 1041401 1041429 1041447

After Pressing Ferrule Diameter Max (mm) Min (mm) 14.45 13.75 19.05 18.10 19.05 18.10 25.65 24.37 25.65 24.37 31.45 29.88 31.45 29.88 37.05 35.20 42.65 40.52 49.00 46.55 54.10 51.40 58.90 55.96 64.00 60.80 68.80 65.36 78.70 74.77 90.40 85.88 104.60 99.37 114.30 108.59 119.35 113.38 125.95 119.65

Bullivants | Page 646 of 692

Revision:: Page: Authority: Reference:

Title: Press Operation –Ferrule Verification & Selection charts

0919 20 of 23 AJT/GD PO‐FV‐SC

Pressing Chart 8 – “Z” Type Steel Ferrules Nominal Rope Diameter (mm)

Limits of Actual Diameter (mm) From

2.5 3 3.5 4 5 6 7 8 9 10 11 12 13 14 16 18

2.5 2.8 3.3 3.8 4.9 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 16.0 18.0

2.7 3.2 3.7 4.3 5.4 6.4 7.4 8.4 9.5 10.5 11.6 12.6 13.7 14.7 16.8 18.9

Range ‘X’ Single Layer Round Strand Rope

Approx Press Load (Tonnes)

Fill Factor 0.36 - 0.62 Use Ferrule Code (Din)

Use Die Code (Din)

2.5 3 3.5 4 5 6 7 8 9 10 11 12 13 14 16 18

4 6 8 11 13 20 30 35 40 45 55 60 70 90 110 130

After Pressing Ferrule Dimensions

DIN Ferrule Diameter

DIN Ferrule Length

Max (mm) 5.10 6.10 7.1 8.10 10.10 12.15 14.15 16.15 18.15 20.20 22.20 24.20 26.20 28.30 32.30 36.40

Max (mm) 14 16 18.00 20 27 29 36 40 45 50 54 59 63 72 81 90

Min (mm) 5.00 6.00 7.00 8.00 10.00 12.00 13.00 16.00 18.00 20.00 22.00 24.00 26.00 28.00 32.00 36.00

Min (mm) 12 14 16 18 23 27 32 36 40 45 50 54 59 63 72 81

NB. * Fill factor represents the ratio between the total metallic area circumscribed by the nominal diameter. † Tensile grade of the wire is not to exceed 2070 Mpa.

GSO / PO-FV-SC / 0220

Bullivants | Page 647 of 692

Revision: Date: Page: Authority: Reference:

Bullivants Pty Ltd

Title: Press Operation –Ferrule Verification & Selection charts

0911 01/09/11 21 of 23 AJT/GD PO‐FV‐SC

Pressing Chart 9 – “ST” Steel Ferrules Nominal Rope Diameter (mm)

16 17 18 19 20 21 22 23 24 25 26 27 28 33 36 40

Limits of Actual Diameter (mm)

From

16.0 16.9 18.0 19.0 20.0 21.1 22.0 23.2 24.0 25.3 26.0 27.4 28.0 33.7 36.0 40.0

16.8 17.9 18.9 19.9 21.0 21.9 23.1 23.9 25.2 25.9 27.3 27.9 29.4 35.9 37.0 42.0

Range ‘X’ Single Layer Round Strand Rope Fill Factor 0.36 – 0.62 Use Ferrule Code

Use Die Code

28 28 32 32 34 34 38 38 42 42 44 44 44 56 60 68

14 15 16 17 17 18 19 20 21 21 22 22 23 28 30 34

Approx Press Load (Tonnes)

After Pressing Ferrule Dimensions

Ferrule Diameter

Ferrule Length

Max (mm) 28.30 30.30 32.30 34.30 34.30 36.40 38.40 40.40 42.40 42.40 44.40 44.40 46.50 56.90

Min (mm) 28.00 30.00 32.00 34.00 34.00 36.00 38.00 40.00 42.00 42.00 44.00 44.00 46.00 56.00

Max (mm)

68.60

68.00

Min (mm)

NB. * Fill factor represents the ratio between the total metallic area circumscribed by the nominal diameter. † Tensile grade of the wire is not to exceed 2070 Mpa.

GSO / PO-FV-SC / 0611

Bullivants | Page 648 of 692

Bullivants Pty Ltd

Title: Press Operation –Ferrule Verification & Selection charts

Revision: Date: Page: Authority: Reference:

0911 01/09/11 22 of 23 AJT/GD PO‐FV‐SC

CHART – 10 Talurit END Stops for VEROPE and other high performance hoist ropes. NB: other wire ropes that are not VEROTOP or VEROTOP P should be “type tested”

GSO / PO-FV-SC / 0611

Bullivants | Page 649 of 692

CRANE SIGNAL CARD MOTION Wire Hoisting Raise

MOTION Wire Hoisting Lower

WHISTLE, BELL OR BUZZER SIGNAL

2 SHORT

1 LONG

MOTION Jib Arm Luffing Boom Up

MOTION Jib Arm Luffing Boom Down

WHISTLE, BELL OR BUZZER SIGNAL

3 SHORT

4 SHORT

MOTION

Slewing Right

Slewing Left

WHISTLE, BELL OR BUZZER SIGNAL

1 LONG, 2 SHORT

1 LONG, 1 SHORT

MOTION Jib-trolley out: telescoping boom extend

MOTION Jib-trolley in: telescoping boom retract

WHISTLE, BELL OR BUZZER SIGNAL

1 LONG, 3 SHORT

1 LONG, 4 SHORT

MOTION

Travel & Traverse

Stop

WHISTLE, BELL OR BUZZER SIGNAL

NOT APPLICABLE

1 SHORT

Bullivants | Page 650 of 692

• R

IGGING

•

EC TI

IN NG •

IN S P

ST I

E • R

RIGCHECK CARD

•

• R E C OV E R

For Product & Inspection Services information call: Asset Management Register: www.bullivants.com/services/beam For locations and more Information regarding Bullivants products & services call or visit on:

www.bullivants.com

This RIGCHECK card has been produced as a ‘guide only’ based on manufacturers specifications and Australian Standards. Bullivants accepts no responsibility should any product fail in service based on information within this card. Item Code: 44203002. All information provided is correct at the time of printing and is subject to change without notice.

Bullivants | Page 651 of 692

STEPS TO PERFORMING A SAFE LIFT

Know the WEIGHT of the load, if not, ask your supervisor

2. Know the APPLICATION requirements

(single or multi leg, basket or choke hitch)

3. Ensure the CORRECT gear is selected for the lift 4. INSPECT all gear before use 5. FLOAT the load and check for BALANCE 6. LIFT the load slowly and controlled 7.

Establish a LANDING PAD with packers to prevent crush of the lifting gear

8. Always RE-INSPECT the gear 9. STORE gear off the ground in a clean dry area Bullivants | Page 652 of 692

LIFTING LIMITATIONS – HOW TO CALCULATE A SAFE ANGLE FOR LIFTING

Base = Length (L) Length of leg

0.5 x Base = Height (H)

0.5 x Length (L) = Height (H)

PREFERRED

MAXIMUM RECOMMENDED

PERMITTED BUT NOT RECOMMENDED Maximum Limit Under Australian Standards

Bullivants | Page 653 of 692

WHY DO ANGLES AFFECT LOADS?

All multi-leg slings exert a horizontal component of force, which increases as the included angle becomes greater.

Example of Variation of sling leg loading with leg angle for a load of 10t

No sling should be used if the included angle exceeds 120º, as beyond this point the forces in the legs drastically increase, as indicated in the diagram.

Loading in sling leg

Horizontal Force NOTE: Do not use multi-leg slings at angles of greater than 120º

Horizontal Force

10 TONNES

Bullivants | Page 654 of 692

STAINLESS STEEL CHAIN SLINGS – SINGLE & MULTI-LEG ASSEMBLIES - AS4991 GRADE 60 CHAIN SIZE MM

STRAIGHT SLING OR ADJUSTABLE SLING WITH NO DERATION

REEVED SLING

1.0 0.4 0.63 0.9 1.25 1.6 2.5 4.25 6.3 8.0 12.0

0.75 0.32 0.5 0.72 1.0 1.28 2.0 3.4 5.04 6.4 9.6

BASKET SLING MAX 60°

STRAIGHT SLING (NOTE 2)

REEVED SLING (NOTES 2 & 3)

ENDLESS CHAIN SLING

60°

Max Angle 60°

1.3 0.52 0.81 1.17 1.62 2.08 3.25 5.52 8.19 10.4 -

1.5 0.6 0.94 1.35 1.87 2.4 3.75 6.37 9.45 12.0 18.0

90°

120°

GRADE 60

WORKING LOAD LIMITS (TONNES) Load Factor > WOX 4-6 WOX 5-6 WOX 6-6 WOX 7-6 WOX 8-6 WOX 10-6 WOX 13-6 WOX 16-6 WOX 20-5 WOX 26-4 +

1.3 0.52 0.81 1.17 1.62 2.08 3.25 5.52 8.19 10.4 -

1.73 0.69 1.09 1.55 2.16 2.76 4.32 7.35 10.9 13.84 -

1.41 0.56 0.85 1.25 1.75 2.2 3.5 5.95 8.8 11.2 -

1.0 0.4 0.63 0.9 1.25 1.6 2.5 4.25 6.3 8.0 -

Notes: 1. Some shortening devices, such as grab hooks may derate the WLL. Advice regarding the appropriate deration should be sought from the manufacturer. 2. The determination of the angle of the multi-leg sling is the largest included angle at the apex of the configuration. 3. Reeved slings and basket slings, in a two leg configuration have a maximum angle for use of 60°. Temperature °C deration

-40° to + 350° none

350° to 700° = only permitted in certain conditions, please contact our technical team for advice.

Bullivants | Page 655 of 692

ALLOY CHAIN SLINGS – SINGLE & MULTI-LEG ASSEMBLIES – AS3775 GRADE T(80) STRAIGHT SLING OR ADJUSTABLE SLING WITH NO DERATION

ADJUSTABLE SLING WITH DERATION (NOTE 1)

1.1

0.8

1.5

1.9

1.6

1.1

1.5

2.5

1.5

1.1

2.0

2.6

2.1

1.5

2.0

3.4 4.5

CHAIN SIZE MM

REEVED SLING

BASKET SLING MAX 60°

STRAIGHT SLING (NOTE 2) 60°

90°

120°

REEVED SLING (NOTES 2 & 3)

BASKET SLING (NOTES 2 & 3)

Max Angle 60°

GRADE T(80)

WORKING LOAD LIMITS (TONNES)

2.0

1.5

2.6

3.5

2.8

2.0

2.6

3.2

2.4

4.1

5.5

4.5

3.2

4.1

7.2

5.3

4.0

6.9

9.2

7.5

5.3

6.9

11.9

8.0

6.0

10.4

13.8

11.3

8.0

10.4

18.0

11.2

8.4

14.6

19.4

15.8

11.2

14.6

25.2

12.5

9.4

16.3

21.6

17.6

12.5

16.3

28.1

15.0

11.3

19.5

26.0

21.2

15.0

19.5

33.8

21.2

15.9

27.6

36.7

29.9

21.2

27.6

47.7

31.5

23.6

41.0

54.5

44.4

31.5

41.0

70.9

-40° to + 200° none

+ 200° to 300° 10.00%

to + 400° 25.00% Bullivants+ 300° | Page 656 of 692

ALLOY CHAIN SLINGS – SINGLE & MULTI-LEG ASSEMBLIES – AS3775 GRADE V(100) CHAIN SIZE MM

STRAIGHT SLING OR ADJUSTABLE SLING WITH NO DERATION

ADJUSTABLE SLING WITH DERATION (NOTE 1)

REEVED SLING

1.0 1.4 1.9 2.5 4.0 6.7 10.0 12.5 14.0 16.0 19.0 21.0 26.5 31.5 40.0

0.8 1.1 1.4 1.9 3.0 5.0 7.5 9.4 10.5 12.0 14.3 15.8 19.9 23.6 30.0

BASKET SLING MAX 60°

STRAIGHT SLING (NOTE 2)

REEVED SLING (NOTES 2 & 3)

BASKET SLING (NOTES 2 & 3)

60°

120°

Max Angle 60°

1.0 1.4 1.9 2.5 4.0 6.7 10.0 12.5 14.0 16.0 19.0 21.0 26.5 31.5 40.0

1.3 1.8 2.5 3.3 5.2 8.7 13.0 16.3 18.2 20.8 24.7 27.3 34.5 41.0 52.0

2.3 3.2 4.3 5.6 9.0 15.1 22.5 28.1 31.5 36.0 42.8 47.3 59.6 70.9 90.0

90°

GRADE V(100)

WORKING LOAD LIMITS (TONNES) 5 6 7 8 10 13 16 18 19 20 22 23 26 28 32

1.3 1.8 2.5 3.3 5.2 8.7 13.0 16.3 18.2 20.8 24.7 27.3 34.5 41.0 52.0

1.7 2.4 3.3 4.3 6.9 11.6 17.3 21.6 24.2 27.7 32.9 36.3 45.8 54.5 69.2

1.4 2.0 2.7 3.5 5.6 9.4 14.1 17.6 19.7 22.6 26.8 29.6 37.4 44.4 56.4

-40° to + 200° none

+ 200° to 300° 10.00%

Bullivants+ 300° | Page 657 of 692 to + 400° 25.00%

GRADE 120 CHAIN SLINGS – SINGLE & MULTI-LEG ASSEMBLIES - AS4991 GRADE 120 STRAIGHT SLING OR ADJUSTABLE SLING WITH NO DERATION

REEVED SLING

Load Factor >

1.0

0.75

1.3

1.73

1.41

1.0

WIN PRO FLEX 7

2.36

1.75

3.0

4.0

3.35

2.36

WIN PRO FLEX 8

3.0

2.25

3.9

5.15

4.25

WIN PRO FLEX 10

5.0

3.75

6.5

8.65

7.1

WIN PRO FLEX 13

8.0

6.0

10.4

13.8

11.2

WIN PRO FLEX 16

12.5

9.35

16.25

21.6

17.5

CHAIN SIZE MM

BASKET SLING MAX 60°

STRAIGHT SLING (NOTE 2) 60°

90°

120°

4 LEG CHAIN SLING WITH LOAD DISTRIBUTOR

REEVED SLING (NOTES 2 & 3)

ENDLESS CHAIN SLING

60°

Max Angle 60°

90°

120°

3.46

2.82

2.0

1.3

1.5

8.15

6.65

4.7

3.0

3.5

3.0

10.4

8.45

6.0

3.9

4.5

5.0

17.3

14.1

10.0

6.5

7.5

8.0

10.4

12.0

12.5

16.25

18.75

GRADE 120

WORKING LOAD LIMITS (TONNES)

WINNER PRO FLEX 200

-60° to -40° not permitted

-40° to +200° none

Above 200° not permitted

Bullivants | Page 658 of 692

HMPE AmSteel®-Blue SLINGS IN ACCORDANCE WITH AS18264/FRS0412 Supplied with Thimble ends or soft loops (with or without protective sleeves) AmSteel®-Blue DIRECT LOADED METHOD OF LOADING SLING Single Included Angle Nom. Dia. (mm)

MBF (kN)

12 16 18 22 24 28 30 32 36 44 56 64 80 88

136.0 211.8 258.0 364.0 436.5 592.5 661.1 736.7 913.3 1343.9 2148.0 2648.7 4031.9 5846.7

CHOKE HITCH Single Round Loaded

Single Square Loaded

2.08 3.24 3.94 5.57 6.67 9.06 10.11 11.27 13.97 20.55 32.84 40.50 61.65 89.40

1.39 2.16 2.63 3.71 4.45 6.04 6.74 7.51 9.31 13.70 21.90 27.00 41.10 59.60

0°

BASKET HITCH

DIRECT LOADED

Single Round Loaded

Multileg

60°

90°

120°

0° to 60°

90°

120°

4.80 7.47 9.10 12.84 15.40 20.90 23.32 25.98 32.21 47.40 75.76 93.42 142.21 206.21

3.91 6.09 7.42 10.46 12.55 17.03 19.01 21.18 26.25 38.63 61.75 76.14 115.90 168.07

2.77 4.32 5.26 7.42 8.90 12.08 13.48 15.02 18.62 27.40 43.79 54.00 82.20 119.20

GROMMETS

Single

*Double

4.43 6.91 8.41 11.87 14.24 19.32 21.56 24.00 29.80 43.84 70.00 86.40 131.52 190.72

7.76 11.95 14.54 20.53 24.63 33.42 37.30 41.52 51.55 75.85 121.10 149.47 227.52 329.94

AmSteel®-Blue

WORKING LOAD LIMITS (TONNES) 2.77 4.32 5.26 7.42 8.90 12.08 13.48 15.02 18.62 27.40 43.79 54.00 82.20 119.20

5.55 8.64 10.52 14.84 17.80 24.16 26.96 30.04 37.24 54.80 87.58 108.00 164.40 238.40

4.80 7.47 9.10 12.84 15.40 20.90 23.32 25.98 32.21 47.40 75.76 93.42 142.21 206.21

3.91 6.09 7.42 10.46 12.55 17.03 19.01 21.18 26.25 38.63 61.75 76.14 115.90 168.07

2.77 4.32 5.26 7.42 8.90 12.08 13.48 15.02 18.62 27.40 43.79 54.00 82.20 119.20

NOTE:

Interfacing components shall not be less than 1.5 times the rope diameter otherwise a 25% deration applies to the WLL as stated within this chart. Bending Ratios for grommets shall not be less than 4 times the rope diameter. *Double Grommets used with a Ramshorn Hook only.

Bullivants | Page 659 of 692

WIRE ROPE SLINGS – SINGLE, TWO, THREE & FOUR LEG WITH FERRULE Secured eyes, using galvanised or black wire rope in accordance with AS1666.1 1570 GRADE FIBRE CORE METHOD OF DIRECT LOADED LOADING SLING Included Angle Nom. Dia. (mm)

MBF (kN)

8 9 10 11 12 13 14 16 18 20 22 24 26 28 32

28.2 35.6 44.0 53.2 63.3 74.3 86.2 113 143 176 213 253 297 345 450

CHOKE HITCH

BASKET HITCH DIRECT LOADED

Round Rectangle Loaded Loaded

0.55 0.70 0.86 1.05 1.23 1.47 1.70 2.22 2.80 3.48 4.20 5.01 5.88 6.81 8.90

0.41 0.52 0.65 0.78 0.92 1.10 1.27 1.67 2.10 2.61 3.15 3.76 4.41 5.11 6.68

0.27 0.35 0.43 0.52 0.61 0.73 0.85 1.11 1.40 1.74 2.10 2.50 2.94 3.40 4.45

Round Load 0°

60°

90°

120°

0° to 60°

90°

120°

0.96 1.21 1.50 1.81 2.14 2.54 2.94 3.85 4.85 6.03 7.27 8.67 10.18 11.79 15.41

0.78 0.99 1.22 1.48 1.74 2.07 2.40 3.14 3.95 4.91 5.92 7.07 8.30 9.61 12.56

0.55 0.70 0.86 1.05 1.23 1.47 1.70 2.22 2.80 3.48 4.20 5.01 5.88 6.81 8.90

CHOKE HITCH ROUND LOAD Single Wrap

Double Wrap

0° to 45°

0° to 60°

1570 GRADE FIBRE CORE

WORKING LOAD LIMITS (TONNES) 1.11 1.40 1.73 2.10 2.47 2.94 3.40 4.45 5.61 6.97 8.40 10.03 11.77 13.63 17.81

0.96 1.21 1.50 1.81 2.14 2.54 2.94 3.85 4.85 6.03 7.27 8.67 10.18 11.79 15.41

0.78 0.99 1.22 1.48 1.74 2.07 2.40 3.14 3.95 4.91 5.92 7.07 8.30 9.61 12.56

0.55 0.70 0.86 1.05 1.23 1.47 1.70 2.22 2.80 3.48 4.20 5.01 5.88 6.81 8.90

0.72 0.91 1.13 1.36 1.61 1.91 2.21 2.89 3.65 4.53 5.46 6.52 7.65 8.86 11.58

Bullivants | Page 660 of 692

1770 GRADE WIRE ROPE CORE METHOD OF DIRECT LOADED LOADING SLING Included Angle Nom. Dia. (mm)

MBF (kN)

8 9 10 11 12 13 14 16 18 20 22 24 26 28 32 36 40 44 48 52 56 60

40.2 51.1 63.1 76.3 90.8 107 124 161 204 252 305 363 426 494 646 817 1010 1220 1450 1710 1980 2270

CHOKE HITCH

BASKET HITCH

Round Rectangle Loaded Loaded

0.78 0.99 1.22 1.48 1.76 2.10 2.40 3.10 4.00 4.90 5.90 7.00 8.30 9.60 12.50 15.80 19.60 24.00 28.00 33.00 38.00 44.00

0.58 0.74 0.92 1.11 1.32 1.55 1.80 2.30 3.00 3.70 4.40 5.30 6.20 7.20 9.40 11.90 14.70 17.70 21.00 25.00 29.00 33.00

0.39 0.49 0.61 0.74 0.88 1.04 1.20 1.56 1.98 2.40 3.00 3.50 4.10 4.80 6.30 7.90 9.80 11.80 14.00 16.60 19.20 22.00

DIRECT LOADED

Round Load 0°

60°

90°

120°

0° to 60°

90°

120°

1.35 1.71 2.10 2.60 3.00 3.60 4.20 5.40 6.80 8.40 10.20 12.20 14.30 16.60 22.00 27.00 34.00 41.00 49.00 57.00 66.00 76.00

1.10 1.40 1.72 2.10 2.50 2.90 3.40 4.40 5.60 6.90 8.30 9.90 11.60 13.50 17.60 22.00 28.00 33.00 40.00 47.00 54.00 62.00

0.78 0.99 1.22 1.48 1.76 2.10 2.40 3.10 4.00 4.90 5.90 7.00 8.30 9.60 12.50 15.80 19.60 24.00 28.00 33.00 38.00 44.00

CHOKE HITCH ROUND LOAD Single Wrap

Double Wrap

0° to 45°

0° to 60°

1770 GRADE WIRE ROPE CORE

WORKING LOAD LIMITS (TONNES) 1.56 1.98 2.40 3.00 3.50 4.10 4.80 6.20 7.90 9.80 11.80 14.10 16.50 19.10 25.00 32.00 39.00 47.00 56.00 66.00 77.00 88.00

1.35 1.71 2.10 2.60 3.00 3.60 4.20 5.40 6.80 8.40 10.20 12.20 14.30 16.60 22.00 27.00 34.00 41.00 49.00 57.00 66.00 76.00

1.10 1.40 1.72 2.10 2.50 2.90 3.40 4.40 5.60 6.90 8.30 9.90 11.60 13.50 17.60 22.00 28.00 33.00 40.00 47.00 54.00 62.00

0.78 0.99 1.22 1.48 1.76 2.10 2.40 3.10 4.00 4.90 5.90 7.00 8.30 9.60 12.50 15.80 19.60 24.00 28.00 33.00 38.00 44.00

1.01 1.29 1.59 1.92 2.30 2.70 3.10 4.10 5.10 6.30 7.70 9.10 10.70 12.40 16.30 21.00 25.00 31.00 37.00 43.00 50.00 57.00

Bullivants | Page 661 of 692

SYNTHETIC SLINGS – FLAT WEBBING SLING – AS1353, ROUNDSLINGS – AS4497

STRAIGHT LIFT MATERIAL COLOUR

MARKED WLL

CHOKED STRAIGHT LIFT

PARALLEL BASKET

BASKET HITCH OR 2, 3 AND 4 LEG SLINGS α = 60°

α = 90°

α°

CHOKE HITCH OR 2, 3 AND 4 LEG SLINGS

α = 120°

Single Wrap α = max 45°

Double Wrap α = max 60°

α°

WORKING LOAD LIMITS (TONNES) Violet

0.8

1.7

1.4

1.38

Green

1.6

3.4

2.8

2.76

Yellow

2.4

5.1

4.2

4.14

Grey

3.2

6.9

5.6

5.52

Red

4.0

8.6

7.0

6.9

Brown

4.8

10.3

8.4

8.28

Blue

6.4

13.8

11.2

11.04

Orange

8.0

17.3

14.1

13.8

WLL’s above 10 tonne - contact Bullivants for support or refer to AS4497 or AS1353. The colour of the working load limit tag shall identify the type of fibre used for round and flat type synthetic slings as follows: Nylon - Green

Polypropylene - Brown

Polyester - Blue

Aramid Polymide - Yellow

Bullivants | Page 662 of 692

SHACKLES – AS2741

Grade S Alloy Bow & Dee Type Shackles (Screw pin & safety pin available)

WLL (TONNES) SIZE d (MM) D (MM) W (MM) B (MM) BOW TYPE L (MM) DEE TYPE L (MM) 0.33

0.50

N/A 22

0.75

1.00

1.50

2.00

3.20

4.70

6.50

8.50

9.50

108

12.00

119

100

13.50

133

113

17.00

146

124

25.00

127

178

146

35.00

146

197

171

45.00

160

222

181

55.00

105

184

267

203

85.00

127

200

330

229

120.00

146

241

381

267

150.00

102

108

165

279

432

318

Sizes up to 1500t available upon request

Bullivants | Page 663 of 692

COLLARED EYEBOLTS & EYENUTS – GRADE 4 – AS2317 SINGLE EYEBOLT OR EYENUT Transverse t (F2) NOMINAL THREAD SIZE

PAIR OF EYEBOLTS OR EYENUTS

Axial t (F1)

Transverse t

Maximum Included Maximum Included Maximum Included Angle 30° t Angle 60° t Angle 90° t

-5º

WORKING LOAD LIMITS (TONNES) M10

0.06

0.25

0.12

0.31

0.20

0.12

M12

0.10

0.40

0.20

0.50

0.32

0.20

M16

0.20

0.80

0.40

1.00

0.64

0.40

M20

0.40

1.6

0.80

2.0

1.28

0.80

M22

0.50

2.0

1.00

2.5

1.60

1.00

M24

0.62

2.5

1.25

3.1

2.0

1.25

M30

1.00

4.0

2.0

5.0

3.2

2.0

M33

1.25

5.0

2.5

6.3

4.0

2.5

M36

1.57

6.3

3.1

7.9

5.0

3.1

M39

1.75

7.0

3.5

8.8

5.6

3.5

M42

2.0

8.0

4.0

10.0

6.4

4.0

M48

2.5

10.0

5.0

12.6

8.0

5.0

M56

3.7

15.0

7.5

18.9

12.0

7.5

M64

5.0

20.0

10.0

25.0

16.0

10.0

M72

6.2

25.0

12.5

31.0

M76

7.5

30.0

15.0

37.0

20.0

12.5

24.0

15.0

Bullivants | Page 664 of 692

Bullivants | Page 665 of 692

Bullivants | Page 666 of 692

Bullivants | Page 667 of 692

Bullivants | Page 668 of 692

MAINTAINING LIFTING EQUIPMENT/CRANE GEAR

The aim of this document is to provide a simple “black and white” explanation of the minimum requirements for inspection and testing of lifting equipment (Crane Gear) showing extracts from the relevant Australian Standards, Legislation and Guidance notes. NB: other state regulations, site rules and or polices may apply

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Bullivants | Page 669 of 692

OH&S REGS CHAPTER 2 ‐ GENERAL DUTIES AND ISSUE RESOLUTION Part 2.1—General Duties 2.1.1

Proper installation, use and maintenance of risk control measures

1) A person who is required by these Regulations to use any particular measure to control risk must ensure that the measure is properly installed (if applicable), used and maintained. Note: Act compliance—sections 21, 22, 23, 24, 26, 29, 30 and 31 (see regulation 1.1.7). 2) This regulation does not apply to a measure required by Part 5.2 (Major Hazard Facilities) or Part 5.3 (Mines). Note: Parts 5.2 and 5.3 are excluded from the operation of this regulation because they contain more specific requirements in relation to the installation, use and maintenance of risk control measures. 2.1.2

Provision of information, instruction and training

1) If these Regulations require an employer to control any particular risk, the employer must provide each employee of the employer who may be exposed to the risk with sufficient information, instruction and training in relation to the following matters as are necessary to enable the employee to perform his or her work in a manner that is safe and without risks to health— a. the nature of the hazard giving rise to the risk; and b. the need for, and the proper use and maintenance of, measures to control the risk. Notes: 1. Act compliance—section 21 (see regulation 1.1.7). 2. Section 21 of the Act also places obligations on an employer in relation to supervision. 2) The obligation imposed by sub regulation (1) is in addition to any other obligation imposed on the employer by these Regulations in relation to the provision of information, instruction and training

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Bullivants | Page 670 of 692

3.5.40 Plant used to lift or suspend loads 1) This regulation does not apply to plant used in connection with— a. the performance of stunt work; or b. the performance of acrobatics; or c. a theatrical performance 2) In respect of plant that is used to lift or suspend people, equipment or materials, an employer must ensure that— a. so far as is reasonably practicable, the plant is specifically designed to lift or suspend those loads; and b. all lifting or suspending is carried out— i.

with lifting attachments that are appropriate to the load to be lifted or suspended; and

ii. within the safe working limits of the plant; and c. subject to subregulation (4), so far as is reasonably practicable, no loads are suspended over, or travel over, a person; and d. loads are lifted or suspended in a way that ensures that the load remains under control during the activity; and e. so far as is reasonably practicable, no load is lifted simultaneously by more than one piece of plant. Note: Act compliance—sections 21 and 23 (see regulation 1.1.7).

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Bullivants | Page 671 of 692

Occupational Health and Safety Act 2004 ‐ SECT 21 No. 107 of 2004 Part 3 ‐ General Duties Relating to Health and Safety Division 2 ‐ Main duties of employers 21. Duties of employers to employees 1) An employer must, so far as is reasonably practicable, provide and maintain for employees of the employer a working environment that is safe and without risks to health. Penalty: 1800 penalty units for a natural person; 9000 penalty units for a body corporate. 2) Without limiting subsection (1), an employer contravenes that subsection if the employer fails to do any of the following‐ a. provide or maintain plant or systems of work that are, so far as is reasonably practicable, safe and without risks to health; b. make arrangements for ensuring, so far as is reasonably practicable, safety and the absence of risks to health in connection with the use, handling, storage or transport of plant or substances; c. maintain, so far as is reasonably practicable, each workplace under the employer's management and control in a condition that is safe and without risks to health; d. provide, so far as is reasonably practicable, adequate facilities for the welfare of employees at any workplace under the management and control of the employer; e. provide such information, instruction, training or supervision to employees of the employer as is necessary to enable those persons to perform their work in a way that is safe and without risks to health.

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Bullivants | Page 672 of 692

23. Duties of employers to other persons 1) An employer must ensure, so far as is reasonably practicable, that persons other than employees of the employer are not exposed to risks to their health or safety arising from the conduct of the undertaking of the employer. Penalty: 1800 penalty units for a natural person; 9000 penalty units for a body corporate. 2) An offence against subsection (1) is an indictable offence. Note: However, the offence may be heard and determined summarily (see section 53 of, and Schedule 4 to, the Magistrates' Court Act 1989).

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Bullivants | Page 673 of 692

Australian Standards AS 2550.1 Cranes, hoists and winches – Safe use 7.3.4

Periodic Inspections

7.3.4.1

General A program of periodic inspection shall be carried out. The frequency of periodic inspection shall be based on the working environment and the frequency and severity of use of the crane. In no circumstances shall the inspection interval exceed 12 months. The inspection and maintenance shall include all items specified in instructions written in accordance with this Standard and include all items specified by the manufacturer for annual inspection together with all routine inspection and maintenance items (see Clause 7.3.3). Notes: 1. As the result of a periodic inspection, a competent person may recommend a major inspection. 2. For all details of inspections for particular types of crane, refer to relevant Part of the AS 2550 series.

7.3.4.2

Non‐positive attachments Where the crane has a non‐positive lifting attachment, suitably qualified personnel shall carry out maintenance according to the manufacturer's recommendations. If such recommendations are not available, then twice‐ yearly maintenance should be carried out. Permanent and electro‐permanent lifting magnets shall undergo a yearly residual magnetism check of the magnet core. Where vacuum lifting attachments are used, the frequency of inspection shall be sufficient to ensure they continue to function as designed.

8.3

Attachments

8.3.1

General Lifting attachments used with cranes shall comply with AS 1418.1 or any Standard listed in Appendix A, or any equivalent international Standard.

8.3.2

Identification and marking Each lifting attachment shall be clearly and permanently marked in accordance with AS 1418.1.

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Bullivants | Page 674 of 692

AS 1353.2‐1997 Flat synthetic‐webbing slings 9.4

Periodic Inspection

9.4.1 General slings shall be inspected by a competent person at intervals of service of not more than three months, and where conditions are severe at shorter intervals. The inspection for any signs of damage shall cover all surfaces along the full length of the slings. 9.5

Inspection records For each sling, a record of every evaluation by a competent person and the details of periodic inspections shall be kept for the life of the sling. The record shall include the date of purchase, the date of introduction to service and general details of the service.

AS 4497.2‐1997 Synthetic‐Round slings 9.4

Periodic Inspection At intervals of service of not more than three months, slings shall be inspected by a competent person; however, where conditions are severe, these intervals should be shorter.

9.5

Inspection Records For each sling, a record of every evaluation by a competent person and the details of periodic inspections shall be kept for the life of the sling. The record shall include the date of purchase, the date of introduction to service and general details of the service.

AS 4991‐2004 Lifting Devices ( Cages, beams , modules ) Section 15 Maintenance, Inspection and Repair 15.1

Inspections

15.1.3 Periodic Lifting devices shall be inspected by a competent person at intervals specified by the manufacturer or, in its absence, at intervals specified by a competent person, taking due consideration of the working environment and the manner in which the lifting device is used.

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Bullivants | Page 675 of 692

AS/NZS 1891.4:2000 Industrial fall‐arrest systems and devices. 9.3

Regular scheduled periodic inspection

9.3.1 General All items of equipment which are in regular use shall be subjected to periodic inspection and where applicable, servicing at either the manufacturers recommended intervals or the intervals given below for each item, whichever is the lesser interval. The inspection and servicing shall be carried out by a competent person. 9.3.2 Belts, harnesses, lanyards and associated equipment. The inspection interval for these items shall be 6 months. Items shall be checked in accordance with manufacturer’s instructions to determine whether there is excessive wear or any other faults liable to render the item unsafe during a fall arrest.

AS 3775.2 2014 Alloy Chain Slings‐Grade T & V Part 2: Care and Use

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Bullivants | Page 676 of 692

AS3775.2 Alloy Chain Slings Grade T & V Section 10 REPAIR

AS1666.2 – 2009 Wire Rope Lifting Slings Sect 10 Inspection of Slings

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Bullivants | Page 677 of 692

AS/NZS 1891.4:2000 Section 9 Inspection, Maintenance and Storage 9.1 Summary of Inspection Requirements in accordance with AS1891.4:2000. The various requirements for the inspection of personal and common use equipment is summarised in Table 9.1. Table 9.1 Activity

Application

Reference

3‐monthly inspection by competent person

Personal equipment including harnesses, lanyard assemblies, connectors, fall arrest devices including common use devices. Fall arrest devices – external inspection only.

6 monthly inspection by competent person*

Belts, harnesses, lanyard assemblies and associated personal equipment.

12 monthly inspection service by competent person*

 Permanently installed anchorages.  Fall arrestor – full service including dismantling where indicated.  Horizontal lifelines and rails including integral components and permanently installed mobile anchorage devices.

In accordance with other Standards

Ropes and slings

Clause 9.7

Inspection on entry or re‐entry into service

All items of personal and common use.

Clause 9.4

Inspection after a fall arrest (and before further use)

All items which have been stressed as a result of a fall.

Clause 9.5

Inspection by operator before and after each use

Clause 9.2

Clause 9.3. 4(a)

* Or more frequently if recommended by the manufacturer or supplier.

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AS 2740 – 2001 WEDGE SOCKETS B3

Inspection Terminations made with wedge‐type sockets shall be inspected after the first and the second loading. Wedge‐type sockets shall be inspected by a competent person, to ensure they are satisfactory for continued use. Prior to being refitted, sockets bodies and socket wedges shall be examined for severe marking and damage. Severely marked, cracked or damaged fittings shall not be re‐used. Wire rope adjacent to a wedge‐type socket shall be examined for breaks in wires, prior to reassembly.

AS 2741 – 2002 SHACKLES B1

Inspection

B1.1

Before use Before use, shackles should be inspected to ensure the following apply: a. The markings are legible. b. The pin is of the correct type. c. The threads of the pin and the body are undamaged. d. The body and the pin are not distorted. e. The body and the pin are not unduly worn. f. The body and the pin are free from nicks, gouges, cracks and corrosion.

B1.2

Periodic Shackles in use should be subject to periodic thorough examination by a competent person. The period between such examinations will depend upon the amount of use.

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AS 3850 – 2015 Concrete Tilt Slab Lifting Equipment 2.5

Reusable Lifting Equipment

2.5.1 General Reusable lifting equipment shall be designed and manufactured to have a limit state factor of 5.0, with the WLL determined in accordance with Clause 2.2. 2.5.2 Lifting clutches Lifting clutches shall be proof tested, certified and individually identified prior to being placed into service. The proof test shall subject the device to a load of 2.0 time its WLL. Inspections of the lifting clutches, prior to each use, shall be conducted to check for wear and deformation. A proof test using a load equal to 1.2 times the WLL shall be conducted and recorded at least at twelve‐monthly intervals. C2.5.2 Suitable identification of lifting clutches may be by permanent marking on the clutch itself or attachment of a durable tag.

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LOCATIONS Sydney

41 Eastern Creek Drive, Eastern Creek NSW 2766

Ph: 1300 LIFTING

Fx: (02) 9625 3351

Newcastle

32 Parker Street, Carrington NSW 2294

Ph: (02) 4940 6900

Fx: (02) 4940 6999

Wollongong

5 Investigator Drive, Unanderra NSW 2526

Ph: (02) 4272 1455

Fx: (02) 4272 1430

Darwin

2 Cato Street, Winnellie NT 0820

Ph: (08) 8984 3299

Fx: (08) 8984 4946

Brisbane

81 Colebard Street West, Acacia Ridge QLD 4110

Ph: (07) 3277 9855

Fx: (07) 3277 2182

Cairns

2/200 Spence Street, Bungalow, Cairns QLD 4870

Ph: (07) 4081 8700

Fx: (07) 4035 4784

Emerald

Cnr of Cameron Rd & Munro Rd, Emerald QLD 4720

Ph: (07) 4980 0900

Fx: (07) 4987 5627

Gladstone

19 Beckinsale Street, Gladstone QLD 4680

Ph: (07) 4841 9600

Fx: (07) 4972 7881

Mackay

43-51 Diesel Drive , Paget QLD 4740

Ph: (07) 4952 2977

Fx: (07) 4952 2792

Mt Isa

1/16 Enterprise Road, Mount Isa QLD 4825

Ph: (07) 4743 2849

Fx: (07) 4743 2876

Toowoomba

Unit 3, 20 Carrington Road, Toowoomba QLD 4350

Ph: (07) 4591 5000

Fx: (07) 4591 5099

Townsville

1-3 Greg Jabs Drive, Garbutt QLD 4814

Ph: (07) 4781 9400

Fx: (07) 4775 2668

Adelaide

1/14 White Rd, Gepps Cross SA 5094

Ph: (08) 8260 4711

Fx: (08) 8260 5610

Melbourne

114 - 116 Boundary Road, Braeside VIC 3195

Ph: (03) 9585 1288

Fx: (03) 9585 8948

Perth

25 Tomlinson Road, Welshpool WA 6106

Ph: (08) 9351 6555

Fx: (08) 9351 8073

Bunbury

5 Halifax Drive, Bunbury WA 6230

Ph: (08) 9725 6380

Fx: (08) 9725 6371

Kalgoorlie

6/46 Great Eastern Hwy, West Kalgoorlie WA 6430

Ph: (08) 9022 0200

Fx: (08) 9021 5760

Port Hedland

4 Manganese Street, Wedgefield WA 6721

Ph: (08) 9160 2500

Fx: (08) 9172 3635

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develops when the rope comes in contact with rough surfaces in the working environment and is obvious to those who handle the line. hltemal abrasion develops as strands move relative to one another within the rope constmction and can be less ob\ioU<; to the tu1trained eye. TI1erefore. frequent inspections of both the i.11temal and extemal surfaces of the rope are recommended. The resulting appearance of abrasion damage is a general "fuzz" along the strands where filaments ha\'e broken and been bmshed away from the body of the rope. Abrasion rates can be controlled through proper use and maintenance of equipment with which the line comes into contact. External abrasion will develop more quickly in situations where the line is exposed to rough surfaces while 1u1der load. Similarly. the rate at which internal abrasion develops progresses when a rope is subject to increasingly severe bends or when rouglt particulate. such as g:111\'el. intrudes into the rope's strncrure. As an HMPE fiber rope begins to abrade. the broken filaments can pro\ide a barrier that protects the 1mbroken filamems from a portion of the damaging contact. lltis can be observed as the rate of accumulated abrasion damage decreasing over time. B. Method ofAbrasion Study 1l1e 11an1re of abrasion damage on synthetic fiber ropes renders steel-wire rope inspection methods impractical. Abrasion damage on steel-wire rope generally results in a loss of material from the outer wires. lltls is easily measttrable either as a reduction in diameter or roru1dness (asynunetrical wear). As the filaments of a rope break. the frayed fiber will tend to stay attached (for some period of time at least) to the body of the rope. These frayed ends will also tend to ha\·e larger \'Oid volwnes between adjacent filaments. For these reasons. a simple diameter measurement will not show tltls loss of material the same way that it ntlght in the case of an abraded steel rope. ll1e diameter of a braided synthetic line is dependent on the tension applied. A change in rope diameter by as much as 10% can be observed based on the load history of the line. Therefore. measurements taken of the same rope with and without tension applied will indicate different le\'els of strength. When volwne meas11rements appear inconclusive a more useful method is req1tlred. A one-inch diameter rope can be made up of over a million individual HMPE filaments making a method of co1u1ting the total munber of broken fibers impractical. Instead. a visual comparison approach \Vas taken: similar to methods used successfully to measure other complex

phenomena. such as s11rface rouglmess. Photog:111plts of used 12-strand HMPE rope samples were collected and orga11ized from lowest to ltlehest le\·els of abrasion. Included were images of both iniemal and extemal abrasion. From these criteria. a series of seven picmres for each type of abrasion were chosen to e\·enly span tl1e range of pote111ial damage. Fig. I is an illustration of the \isual comparison method 1.LSed to detemtlne abrasion levels. Based on tltls visual scale. a rope sample can be compared to a range of intental and extemal abrasion criteria and recei\·e a munerical ranking. Tltls would be a co1tsistent way to conumut.icate the \isual appearance of abraded ropes across various industries and utspectors. In addition. tltls scale pro\ides a way to relate levels of intemal/extemal abrasion to residual strength of dantaged rope samples. Utilizing five years of well docmnented test resuhs on rope samples 1LSed in a variety of applications. a correlation was made between abrasion level and residual strength. T11e sn1dy was lintlted to one rope product u1 particular: AmSteel�-Blue. a 12-strand single braid. 100% Dy:neema� rope. TI1e majority of samples tested were 1LSed as conuuercial marine mooring and tug tow lines. T11e process required an initial screening of the test reports to ensure that abrasion dantage was the predominant factor causing the reduction in rope strength. In a significant munber of cases. utspection of the test samples showed other dantage modes u1 addition to abrasion such as cutting. meltu1g. compression and se\·ere twist. Other factors that caused disqualification from the sample pool u1clude abnomtal break locations. non-standard testu1g methods. and poor documentation of testu1g and/or line condition. T11e result was the elimination of 75% of the test results as they did not clearly docmnent abrasion as the sole cmLSe of strength. Visual ranking was then applied to the remaining pool of 51 test sample repo11s that indicated abrasion as the only so1tree of stre112th reduction. TI1ese tests were documented \\>ith multiple picn1r�s of the u1temal and extenial conditio1ts of the rope. Every report 1LSed u1 tit.is e\'aluation had images taken of the most se\'ere abrasion observed 011 the sample. Six synthetic rope experts were presented the ,isual comparator \\-ith sample unages from each report and asked to rank ullernal and extental abrasion for each. 1l1e experts were u1stmcted to choose the images showing the most damaged section of line for each sample upon \\it.ich to make their ranki.ng. TI1e resulting data was a collection of 306 obserrntions with values for sample resid11al strength. intemal abrasion leYel. and extemal abrasion level.

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By limiting the investigation to the one particular construction of rope. the AmSteels.·Blue product. we reduce the munber of uncontrolled variables. Each of the 12-strands making up the braid is composed of Dyneema® fiber misted together. Depending on the diameter of the product. these strands may be made up of a single bw1dle of misted fiber or a collection of multiple twisted yams. TI1e final rope is coated with an abrasion resistant urethane forumla designed to improve wear life. TI1e twist ratio. yam/strand size. coating. and braiding angle can vary between different HMPE ropes. TI1cse ,011Stn1,tional changes can have a drastic effect on many characteristics of the rope. For example. by lengthening the braid angle the stret1gth efficiency can be increased. HoweYer. th.is will result in a looser rope construction that may be more susceptible to wear. TI1e findings from this investigation are therefore valid only for this particular product. C. Analysis ofFindings

Evaluation of the collected infomiation begins with a sn1dy into how the data is organized. Each data point gathered from this investigation falls into one of 49 separate states. Each distinct state is defined by two munerical values ranging from 1 to 7 . TI1e first value placed on the sample' observed was based on the level of intenial abrasion as visually identified by the expert. TI1e second defining value represents the observed sampJe·s extemal abrasio1L On average, a data set of 300 points with 49 potential states would result in six residual strength data points per state. In reality. the data is organized less 1ulifonnly among the stales. For example, the state defined by a value of "I" for extenial abrasion and "7" for internal abrasion has no data points. TILis indicates a strong correlation between internal and external abrasioIL which niakes an application resulting in a rope exhibiting the llighest level of intenial abrasion without any visible extental abrasion difficult to im.1gine. hl order to correlate rope strength to abrasion state with a tighter tolerance interval lligher sample cow1ts per state are needed. Tims various separate states were combined. Tius investigation looked at combining the data into three. fiYe. and

seYetl collections of data. or bins. TI1e method used to combine states sorted them based on their largest ranked abrasion type. For example. the state defined by an intemal abrasion value of 3 and level 5 extenial abrasion would be sorted into the same bin as the state defined by an intemal abrasion ranking of 5 and extemal abrasion value of 4 as le,·el S is the llighest damage level in both cases. After detenni.ning the munber of samples per bin in each arrangement. statistical means for each bin. and standard deviations. tolerance Ii.nuts were calculated. These were based on a 90% confidence on 90% of the total population falling with.in the limits. Due to the relatively small number of data points collected. the 3-bin arrangement provides the tightest tolerances as the munber of sa1nples per. bin allows for a lower statistical ..K.. value. \\i1ere ..K. represents the statistical multiplier based on sample size. and similar standard deviations. TI1e abrasion comparison tool was not modified to only show these three leYels in the interest of niaintai.iung lligl1er resolution when tracking rope wear. As more data is collected iii later sn1dies. tllis may lead 10 a lugher resolution model in the funire. As Fig. 2 shows. the bins were arranged such that the llighest damage le,·el was 2. 5. and 7. By using all 306 data points developed by the experts· ,isual analysis of test reports. between 60 and 120 residual strength results were arranged in each bi.IL TI1e graph sbo\',ll in Fig. 3 illustrates the average percentage of strength retention for samples in each bi.ii with· their tolerance limits. This shows a clear decrease in stren2th as either intemal or extemal abrasion levels i.i1crease. In addition. the lower tolerance li.inits provide a level of confidence in the strength lost in a used rope based solely on the leYel of abrasion. Titrou11.h a visual rankimt of a le,·el 2 abrasion ranking of a used AmSteels,•Blue li.i1e. you can state with 90% confidence that the rope's strength is aboYe 75.6% of new rope strength. V.

CUTIING OF HMPE ROPES

A. Definition o/C11tli11g Damage

Another type of mechrulical daniage that HMPE lines can ex')}erience is the complete. or partial. cutti.i1g of stmnds. Unlike

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or strand generally occurs as a singular event. In the e\·enl that a rope is cm during use. the question is whether it can continue to be used or if it needs to be retired. To simulate tlus. the test method used involved cycling the rope IO tiines to 50% of the rope• s published nmumum breaking strength. relaxing the sample. applying the required damage. and then pulling directly to break. Tlus simulates a scenario where the rope has been used for some time before beimt dama2ed. Once the damage is inflicted and discovered. dtui11g the relaxed pltase of testing. the question becomes. ··What is the rope·s current strength?"' By pulling the rope immediately to break after it has been dantaged. the instantaneous strength loss of the 11sed rope can be detemU11ed. Various lengths and sizes of ropes were used in this investigation. A.II testing \\i1ere multiple strands were cut on a single sample rope in\·olved the cutting of two strands of the same twist. Tius was theorized. and shown iii testit12. to cause the most severe loss it1 strength due to the 1U1balan�ing of the rope. TI1e three phases of testit1g are outlined below:

extemal abrasion. cutting refers to extremely localized damage where a significant percentage of the filaments in a rope are severed in a single location. Tius causes strength loss due to the overall decrease in fiber content as well as an unbalancing of the twist levels in the rope. For this reason. it is important to ensur-e that a rope does not come in contact with any sharp surfaces. especially while under significant tension. When deciding whether or not lo retire an HMPE line, the separation of localized damage becomes an iniportant factor. Cutting two adjacent strands has a greater impact on the rope strength than cutting two strands on opposite ends of the rope. Tiiis is due to traction between adjacent strands leading 10 transfer of tension and load sharing. Tius study attempted 10 quantify not only the effect on strength that the number of cul strands bas. but the effect oftheir separation distance as well. B. Method of Cut Strand Sh1dy TI1e first challenge in the testing procedure is maintaiiung a consistency in the amow1t of damage applied. Each target strand to receive cutting damage must receive the same percentage of fiber reduction. TI1e result of using tlus constmction is that there is no way to count out an exact mllllber of fibers in groupings of less than an entire strand. Therefore. all damage inflicted on the testing samples is in tuuts of entire cut strands. Titis study ii1vesti gated tensile strength of new rope with controlled cutting damage inflicted. Specimens were tested with a single .cut strand as well as two cut strands, both adjacent and separated. The separation between cut strands was measured in lay lengths. where a single lay length is defined as the distance for a strand to make one revolution around the axis of the rope. As opposed to generalized abrasion. cutting damage is isolated iu location as well as in time. Titat is. cutting of a rope

•

3/8"' diameter samples. short separation lengths

•

3ts·· diameter samples. Jong separation lengths

•

1 •• diameter samples. sho11 separation lengths

Due to test bed litnitations. testing could not be perfonned on large diameter ropes at long lengths. Thus testit1g was done to thoroughly investi gate the effects of cuttit1g on small diameter samples first. Once a relationsliip was identified. larger diameter samples could be itwestigated witlm1 the range of capabilities and co mpared to verify that the strength retention trends are similar for both sizes of rope as the two sizes are manufactured by slightly different methods. TI1e small size has all of the fiber in a strand together it1 a sit1gle twist stage. \,iule the larger rope strands are made up of multiple first m-ist yam_s twisted together.

C. Analysis ofFindings Testing results showed sigiuficant effects of cuttii1g damage on residual rope strength. As shown it1 Table I . damaged samples were fo1md to have lower average strengths than the 1u1da111aged san.1ples. All damaged sample strengths were compared to the average tested strength for the new rope samples . Cut Strand Test Results Sample Size

Single o,t

l Cuts (no separation)

2 Oils (separated)

3/8'" (short)

92.3%

76.4%

83.1%

3/s·· (long)

87.1%

82.3%

98.7%

79.1%

65.4%

76.3%

Table I. Average residual strength of dam.1ged � samples as compa.red to tesied avm1g� new� brnking strmgth.

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Contrary to initial thinking. as the separation between two points of damage inflicted to the rope is increased the average breaking strength of the sample will 1101 approach that of a sample with a single point of damage. This is due to the rope always failing at the weak point with the lower strength value. In the case of a nonnal distribution of breaking strengths measured for tl1e same construction of rope with a single weak point. roughly half of the samples will break higher than average and half will break lower. With a situation involving two independent potential failure points. the point with a lower breaking strength \viii cause the sample to break first. The result is that the wear points that statistically would break above average are only >witnessed when both points are above average. The strength will approach a sligl1tly lower \,due and the standard deviation in the average wilJ be less than that of a sample \\�th a single weak point. As shown by the probability density curves in Fig.5, this drives the overall average for the rope breaking strength down witholll any interaction taking place between the two cut strands. Varying the separation distance for the small diameter samples did not show a statistically significant effect on the rope breaking strengtll. As is evident in Fig. 6. changing tl1e length from two to l O Jay lengths did not change the breaking strength significantly. However. initial findin� 011 small diameter sample testing shows a trend towards the theoretical Probability Density Function Curves Single 1md Two Cut (h1depende11t) Probabilities

mean expected based on the statistical model. The a\'erag:e breaking strengths folu1d for samples with two separated damage locations are all higl1er than the strength of ropes with ri,·o adjacent cut strands. It is apparent that there has been au increase in breaking strength of the rope by adding some amount of separation between the strands \\ith inflicted damage.

--------u-.6 ,-----.---------

Testing on the one-inch diameter samples showed a similar trend in the effect of separation on residual strength. The results shown in Fig. 7 illustrate the change in a\'erage breaking strength for the lines ,,ith multiple cul strands as compared to those with a single cut. The samples with separated cuts had a consistent six lay lengths bet\veen each of the locations where damage was inflicted. Three samples were tested for each condition to detennine the a,·erag:e.

-4

-2

Standard Deviations Fig. 5. Solid cmvc is a nOllD&!i=I probability density funclico (PDF) for a nonnal distribu!ico (the avcnigc breaking strength of samples \\�th a sing!.- cul strand is assumed to follow Ibis distribulico) \Wile the dashed cur.e is th. resulting PDF for the avenigc strength of a sample with two indcpcndcnc \\ffl points.

One \'ariation that was apparent \\ith the different diameters was the percentage of breaking strength lost due to cutting damage. On the small diameter samples a single cut strand resulted in an average breaking strength almost 10%, lower than that of the undamaged samples. ll1e a\·erage strength obsen-ed \\-i1en t\\'O adjacent strands were · cut was almost 25% less th,m that of the control samples. hl the one inch diameter testing. a\'erage breaking strengths for the single and t\vo adjacent cut tests were 20% and 35% Jess than the control average respecti,·ely. ll1is shows a significantly higher effect of cutting: damage on the strength of the larger diameter rope. h1vestiga1ions into the long separation length on small diameter samples did not pro\ide any useful infonnation. Testing: showed an tuiacceptable ammu1t of \·ariation. In an effort to reach longer sample lengths. testing was perfonned on

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VI.

CONCLUSIONS

This investigation has provided ,·aluable insight into the inspection methods and criteria for HMPE ropes affected by mechanical wear. Howe\'er. further testing will continue to improve the tUlderstanding of strength loss in used fiber ropes. Mo\'ing forward. residual testing of abraded lines will be evaluated based on the ,isual inspection tool and added to the data collected in this study. By continually analyzing these results we can better tmderstand how the ,isual appearance of abraded HMPE lines correlates to residual strength. Future investi2ation will focus on the combination of these two mechanical -wear modes as well. The testing plan deliberately separated ihese two wear modes to make consistent and repeatable measurement possible. This required the disqualification of any testing reports that show evidence of both abrasion and cutting damage for this u1vestigation. However. these test reports can be used in a future mixed mode model u1vestigation.

a machine test-bed 'with a load capacity much higher than the strength of the ropes. As such. there may have been a resolution and accuracy issue in the testing equipment that accounted for the spurious results.

Residual strength of used rope needs to be estimated for retirement and safety. In many applications !lccurate records of usage is tmattainable and therefore effecti\'e inspection and retirement criteria should be independent of service history. By testing abraded samples from the field we were able to correlate visual ranking of abrasion-to-strength ,,..ithout relying on usage records. Using the methods developed u1 this study we have the ability to make strength estimates ,,ithout requiring destrnctive testing.

REFERENCES [I] Cordage lnsti!Ute. fibtt Rope inspection and Retir=t Critma.. bnp:/lwww.rop«orcl.com/cordagc/publications/CI200 I .pdf. 2001-2004. pp. 27-29 (Appnidix q.

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SECTION 15 – FST Kit

Dividers

Chain Link Gauge

WLL Chart

Sheave Gauges Thread Gauges Torch

Steel Ruler

Tape Measure Riggers Handbook

Kit Bag

15 - 9

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