Table of Contents. Inspection and Removal criteria for: Hooks Reprinted from ASME B P. 6 to 8

Transcription

1 Table of Contents Inspection and Removal criteria for: Slings: Wire, Chain, Synthetic Round and Synthetic Web Reprinted from ASME B P. 2 to 5 Inspection and Removal criteria for: Hooks Reprinted from ASME B P. 6 to 8 Inspection and Removal criteria for: Below-the-Hook Devices Reprinted from ASME B P. 8 to 9 Inspection and Removal criteria for: Manually Lever Operated Devices Reprinted from ASME B P. 9 to 15 Inspection and Removal criteria for: Rigging Hardware Reprinted from ASME B P. 15 to 18 Wire Rope Slings Reference Chart P. 19 Wire Rope Configurations P. 20 Chain Slings Reference Chart P. 21 Chain Sling Type Naming Code P. 22 to 23 Recommended Standard Specification for Synthetic Web Slings Reprinted from WSTDA-T-1 P. 24 to 25 Cargo Securement - Summary of changes Reprinted from National Safety Code 10 - Cargo Securement P. 26 to 30

2 2 All Macline Slings, Hooks, Below the Hook Devices, Manual Lever Operated Hoists and Rigging Hardware products follow the inspection and removal criteria set out by ASME. Below, you will find the criteria for both as it pertains to the following areas: Slings: Wire, Chain, Synthetic Round and Synthetic Web - Reprinted from ASME B Alloy Steel Chain Slings: Initial Inspection Prior to use, all new, altered, modified, or repaired slings shall be inspected by a designated person to verify compliance with the applicable provisions of this Chapter Frequent Inspection (a) A visual inspection for damage shall be performed by the user or other designated person each day or shift the sling is used. (b) Conditions such as those listed in para or any other condition that may result in a hazard shall cause the sling to be removed from service. Slings shall not be returned to service until approved by a qualified person. (c) Written records are not required for frequent inspections Periodic Inspection (a) A complete inspection for damage of the sling shall be periodically performed by a designated person. Each link and component shall be examined individually; taking care to expose and examine all surfaces including the inner link surfaces. The sling shall be examined for conditions such as those listed in para and a determination made as to whether they constitute a hazard. (b) Periodic Inspection Frequency. Periodic inspection intervals shall not exceed 1 year. The frequency of periodic inspections should be based on (1) frequency of sling use (2) severity of service conditions (3) nature of lifts being made (4) experience gained on the service life of slings used in similar circumstances (c) Guidelines for the time intervals are (1) normal service yearly (2) severe service monthly to quarterly (3) special service as recommended by a qualified person (d) A written record of the most recent periodic inspection shall be maintained and shall include the condition of the sling Removal Criteria An alloy steel chain sling shall be removed from service if conditions such as the following are present: (a) missing or illegible sling identification (see Section 9-1.7). (b) cracks or breaks. (c) excessive wear, nicks, or gouges. Minimum thickness on chain links shall not be below the values listed in Table 6. (d) stretched chain links or components. (e) bent, twisted, or deformed chain links or components. (f) evidence of heat damage. (g) excessive pitting or corrosion. (h) lack of ability of chain or components to hinge (articulate) freely. (i) weld splatter. (j) for hooks, removal criteria as stated in ASME B (k) for rigging hardware, removal criteria as stated in ASME B (l) other conditions, including visible damage, that cause doubt as to the continued use of the sling.

3 Wire Rope Slings: Initial Inspection Prior to use, all new, altered, modified, or repaired slings shall be inspected by a designated person to verify compliance with the applicable provisions of this Chapter Frequent Inspection (a) A visual inspection for damage shall be performed by the user or other designated person each day or shift the sling is used. (b) Conditions such as those listed in para or any other condition that may result in a hazard shall cause the sling to be removed from service. Slings shall not be returned to service until approved by a qualified person. (c) Written records are not required for frequent inspections Periodic Inspection (a) A complete inspection for damage to the sling shall be periodically performed by a designated person. Inspection shall be conducted on the entire length including splices, end attachments, and fittings. The sling shall be examined for conditions such as those listed in para and a determination made as to whether they constitute a hazard. (b) Periodic Inspection Frequency. Periodic inspection intervals shall not exceed 1 year. The frequency of periodic inspections should be based on (1) frequency of sling use (2) severity of service conditions (3) nature of lifts being made (4) experience gained on the service life of slings used in similar circumstances (c) Guidelines for the time intervals are (1) normal service yearly (2) severe service monthly to quarterly (3) special service as recommended by a qualified person (d) A written record of the most recent periodic inspection shall be maintained Removal Criteria A wire rope sling shall be removed from service if conditions such as the following are present: (a) missing or illegible sling identification (see Section 9-2.7) (b) broken wires (1) for strand-laid and single-part slings, ten randomly distributed broken wires in one rope lay, or five broken wires in one strand in one rope lay (see Fig. 2) (2) for cable-laid slings, 20 broken wires per lay (see Fig. 8) (3) for six-part braided slings, 20 broken wires per braid (see Fig. 4) (4) for eight-part braided slings, 40 broken wires per braid (see Fig. 4) (c) severe localized abrasion or scraping (d) kinking, crushing, birdcaging, or any other damage resulting in damage to the rope structure (e) evidence of heat damage (f) end attachments that are cracked, deformed, or worn to the extent that the strength of the sling is substantially affected (g) severe corrosion of the rope, end attachments, or fittings (h) for hooks, removal criteria as stated in ASME B30.10 (i) for rigging hardware, removal criteria as stated in ASME B30.26 (j) other conditions, including visible damage, that cause doubt as to the continued use of the sling Synthetic Rope Slings: Initial Inspection Prior to use, all new, altered, modified, or repaired slings shall be inspected by a designated person to verify compliance with the applicable provisions of this Chapter Frequent Inspection (a) A visual inspection for damage shall be performed by the user or other designated person each day or shift the sling is used. (b) Conditions such as those listed in para or any other condition that may result in a hazard shall cause the sling to be removed from service. Slings shall not be returned to service until approved by a qualified person. (c) Written records are not required for frequent inspections. 3

4 Periodic Inspection (a) A complete inspection for damage to the sling shall be periodically performed by a designated person. Each sling and component shall be examined individually, taking care to expose and examine all surfaces. Inspection shall be conducted on the entire length including splices, end attachments, and fittings. The sling shall be examined for conditions such as those listed in para and a determination made as to whether they constitute a hazard. (b) Periodic Inspection Frequency. Periodic inspection intervals shall not exceed 1 year. The frequency of periodic inspections should be based on (1) frequency of sling use (2) severity of service conditions (3) nature of lifts being made (4) experience gained on the service life of slings used in similar circumstances (c) Guidelines for the time intervals are (1) normal service yearly (2) severe service monthly to quarterly (3) special service as recommended by a qualified person (d) A written record of the most recent periodic inspection shall be maintained Removal Criteria A synthetic rope sling shall be removed from service if conditions such as the following are present: (a) missing or illegible sling identification (see Section 9-4.7) (b) cuts, gouges, areas of extensive fiber breakage along the length, and abraded areas on the rope (c) damage that is estimated to have reduced the effective diameter of the rope by more than 10% (d) uniform fiber breakage along the major part of the length of the rope in the sling such that the entire rope appears covered with fuzz or whiskers (e) inside the rope, fiber breakage, fused or melted fiber (observed by prying or twisting to open the strands) involving damage estimated at 10% of the fiber in any strand or the rope as a whole (f) discoloration, brittle fibers, and hard or stiff areas that may indicate chemical damage, ultraviolet damage, or heat damage (g) dirt and grit in the interior of the rope structure that is deemed excessive (h) foreign matter that has permeated the rope and makes it difficult to handle and may attract and hold grit (i) kinks or distortion in the rope structure, particularly if caused by forcibly pulling on loops (known as hockles) (j) melted, hard, or charred areas that affect more than 10% of the diameter of the rope or affect several adjacent strands along the length that affect more than 10% of strand diameters (k) poor condition of thimbles or other components manifested by corrosion, cracks, distortion, sharp edges, or localized wear (l) for hooks, removal criteria as stated in ASME B30.10 (m) for rigging hardware, removal criteria as stated in ASME B30.26 (n) other visible damage that causes doubt as to the strength of the sling Synthetic Webbing Slings: Initial Inspection Prior to use, all new, altered, modified, or repaired slings shall be inspected by a designated person to verify compliance with the applicable provisions of this Chapter Frequent Inspection (a) A visual inspection for damage shall be performed by the user or other designated person each day or shift the sling is used. (b) Conditions such as those listed in para or any other condition that may result in a hazard shall cause the sling to be removed from service. Slings shall not be returned to service until approved by a qualified person. (c) Written records are not required for frequent inspections Periodic Inspection (a) A complete inspection for damage to the sling shall be periodically performed by a designated person. Each sling and component shall be examined individually, taking care to expose and examine all surfaces. The sling shall be examined for conditions such as those listed in para and a determination made as to whether they constitute a hazard. (b) Periodic Inspection Frequency. Periodic inspection intervals shall not exceed 1 year. The frequency of periodic inspections should be based on (1) frequency of sling use (2) severity of service conditions (3) nature of lifts being made (4) experience gained on the service life of slings used in similar circumstances

5 5 (c) Guidelines for the time intervals are (1) normal service yearly (2) severe service monthly to quarterly (3) special service as recommended by a qualified person (d) A written record of the most recent periodic inspection shall be maintained Removal Criteria A synthetic webbing sling shall be removed from service if conditions such as the following are present: (a) missing or illegible sling identification (see Section 9-5.7) (b) acid or caustic burns (c) melting or charring of any part of the sling (d) holes, tears, cuts, or snags (e) broken or worn stitching in load bearing splices (f) excessive abrasive wear (g) knots in any part of the sling (h) discoloration and brittle or stiff areas on any part of the sling, which may mean chemical or ultraviolet/sunlight damage (i) fittings that are pitted, corroded, cracked, bent, twisted, gouged, or broken (j) for hooks, removal criteria as stated in ASME B30.10 (k) for rigging hardware, removal criteria as stated in ASME B30.26 (l) other conditions, including visible damage, that cause doubt as to the continued use of the sling Synthetic Round Slings: Initial Inspection Prior to use, all new, altered, modified, or repaired slings shall be inspected by a designated person to verify compliance with the applicable provisions of this Chapter Frequent Inspection (a) A visual inspection for damage shall be performed by the user or other designated person each day or shift the sling is used. (b) Conditions such as those listed in para or any other condition that may result in a hazard shall cause the sling to be removed from service. Slings shall not be returned to service until approved by a qualified person. (c) Written records are not required for frequent inspections Periodic Inspection (a) A complete inspection for damage to the sling shall be periodically performed by a designated person. Each sling and component shall be examined individually, taking care to expose and examine all surfaces. The sling shall be examined for conditions such as those listed in para and a determination made as to whether they constitute a hazard. (b) Periodic Inspection Frequency. Periodic inspection intervals shall not exceed 1 year. The frequency of periodic inspections should be based on (1) frequency of sling use (2) severity of service conditions (3) nature of lifts being made (4) experience gained on the service life of slings used in similar circumstances (c) Guidelines for the time intervals are (1) normal service yearly (2) severe service monthly to quarterly (3) special service as recommended by a qualified person (d) A written record of the most recent periodic inspection shall be maintained Removal Criteria A synthetic roundsling shall be removed from service if conditions such as the following are present: (a) missing or illegible sling identification (see Section 9-6.7) (b) acid or caustic burns (c) evidence of heat damage (d) holes, tears, cuts, abrasive wear, or snags that expose the core yarns (e) broken or damaged core yarns (f) weld splatter that exposes core yarns (g) roundslings that are knotted (h) fittings that are pitted, corroded, cracked, bent, twisted, gouged, or broken (i) for hooks, removal criteria as stated in ASME B30.10 (j) for rigging hardware, removal criteria as stated in ASME B30.26 (k) other conditions, including visible damage, that may cause doubt as to the continued use of the sling

6 Hooks: 6 Hooks - Reprinted from ASME B Inspection Inspection procedure and record keeping requirements for hooks in regular service shall be governed by the kind of equipment in which they are used. When more stringent requirements for hooks are stated in standards for the specific equipment, they shall take precedence over the following. Otherwise, there shall be an initial inspection, and two general classifications based upon intervals at which examination shall be performed. The classifications are herein designated as initial, frequent, and periodic, with intervals between examinations defined as follows Initial Inspection Prior to use, all new, altered, modified, or repaired hooks shall be inspected by a designated person to verify compliance with the applicable provisions of this Volume. Written records are not required Frequent Inspection (a) Frequent inspections shall include observations during operation. A visual inspection shall be performed by the user or designated person for conditions listed in para (b) A designated person shall determine whether conditions found during the inspection constitute a hazard and whether a more detailed inspection is required. (c) Semipermanent and inaccessible locations where frequent inspections are not feasible shall have periodic inspections performed, at a frequency as determined by a qualified person. (d) The inspection intervals should be based on (1) frequency of hook use (2) severity of service conditions (3) nature of lifts being made (4) experience gained on the service life of hooks used in similar circumstances (5) guidelines for the time intervals are (a) normal service monthly (b) heavy service weekly to monthly (c) severe service daily to weekly (e) Conditions such as those listed in para or any other condition that may result in a hazard shall cause the hook to be removed from service. Hooks shall not be returned to service until approved by a qualified person. (f) Written records are not required Periodic Inspection (a) A complete inspection of the hook shall be performed by a designated person. NOTE: Some disassembly may be required. The hook shall be examined for conditions such as those listed in para and a determination made as to whether they constitute a hazard. (b) Periodic Inspection Frequency. Periodic inspection intervals shall not exceed 1 yr. except as approved by a qualified person. The inspection intervals should be based on (1) frequency of hook use (2) severity of service conditions (3) nature of lifts being made (4) experience gained on the service life of hooks used in similar circumstances (5) guidelines for the time intervals are (a) normal service yearly with equipment in place (b) heavy service semiannually, with equipment in place unless external conditions indicate that disassembly should be done to permit detailed inspection monthly to quarterly (c) severe service quarterly, as in heavy service [see para (b)(5)(b)], except that the detailed inspection may show the need for a nondestructive type of testing (c) Hooks shall not be returned to service until approved by a qualified person. (d) Written records are required Removal Criteria Hooks shall be removed from service if damage such as the following is visible and shall only be returned to service when approved by a qualified person: (a) missing or illegible hook manufacturer s identification or secondary manufacturer s identification (b) missing or illegible rated load identification (c) excessive pitting or corrosion (d) cracks, nicks, or gouges

7 (e) wear any wear exceeding 10% (or as recommended by the manufacturer) of the original section dimension of the hook or its load pin (f) deformation any visibly apparent bend or twist from the plane of the unbent hook (g) throat opening any distortion causing an increase in throat opening of 5% not to exceed 1 4 in. (6 mm) (or as recommended by the manufacturer) (h) inability to lock any self-locking hook that does not lock (i) inoperative latch (if required) any damaged latch or malfunctioning latch that does not close the hook s throat (j) damaged, missing, or malfunctioning hook attachment and securing means (k) thread wear, damage, or corrosion (l) evidence of excessive heat exposure or unauthorized welding (m) evidence of unauthorized alterations such as drilling, machining, grinding, or other modifications Hooks - Miscellaneous: Inspection Inspection procedure and record keeping requirements for hooks in regular service shall be governed by the kind of equipment in which they are used. When more-stringent requirements for hooks are stated in standards for the specific equipment, they shall take precedence over the following. Otherwise, there shall be an initial inspection, and two general classifications based upon intervals at which examination shall be performed. The classifications are herein designated as initial, frequent, and periodic, with intervals between examinations defined as follows Initial Inspection Prior to use, all new, altered, modified, or repaired hooks shall be inspected by a designated person to verify compliance with the applicable provisions of this Volume. Written records are not required Frequent Inspection (a) Frequent inspections shall include observations during operation. A visual inspection shall be performed by the user or designated person for conditions listed in para (b) A designated person shall determine whether conditions found during the inspection constitute a hazard and whether a more-detailed inspection is required. (c) Semipermanent and inaccessible locations where frequent inspections are not feasible shall have periodic inspections performed, at a frequency as determined by a qualified person. (d) The inspection intervals should be based on (1) frequency of hook use (2) severity of service conditions (3) nature of lifts being made (4) experience gained on the service life of hooks used in similar circumstances (5) guidelines for the time intervals are (a) normal service monthly (b) heavy service weekly to monthly (c) severe service daily to weekly (e) Conditions such as those listed in para or any other condition that may result in a hazard shall cause the hook to be removed from service. Hooks shall not be returned to service until approved by a qualified person. (f) Written records are not required Periodic Inspection (a) A complete inspection of the hook shall be performed by a designated person. NOTE: Some disassembly may be required. The hook shall be examined for conditions such as those listed in para and a determination made as to whether they constitute a hazard. (b) Periodic Inspection Frequency. Periodic inspection intervals shall not exceed 1 yr. except as approved by a qualified person. The inspection intervals should be based on (1) frequency of hook use (2) severity of service conditions (3) nature of lifts being made (4) experience gained on the service life of hooks used in similar circumstances (5) guidelines for the time intervals are (a) normal service yearly with equipment in place (b) heavy service semiannually, with equipment in place unless external conditions indicate that disassembly should be done to permit detailed inspection monthly to quarterly (c) severe service quarterly, as in heavy service [see para (b)(5)(b)], except that the detailed inspection may show the need for a nondestructive type of testing 7

8 (c) Hooks shall not be returned to service until approved by a qualified person. (d) Written records are required Removal Criteria Hooks shall be removed from service if damage such as the following is visible and shall only be returned to service when approved by a qualified person: (a) missing or illegible hook manufacturer s identification or secondary manufacturer s identification (b) missing or illegible rated load identification (c) excessive pitting or corrosion (d) cracks, nicks, or gouges (e) wear any wear exceeding 10% (or as recommended by the manufacturer) of the original section dimension of the hook or its load pin (f) deformation any visibly apparent bend or twist from the plane of the unbent hook (g) throat opening any distortion causing an increase in throat opening of 5% not to exceed 1 4 in. (6 mm) (or as recommended by the manufacturer) (h) inability to lock any self-locking hook that does not lock (i) inoperative latch (if provided) any damaged latch or malfunctioning latch that does not close the hook s throat (j) damaged, missing, or malfunctioning hook attachment and securing means (k) thread wear, damage, or corrosion (l) evidence of excessive heat exposure or unauthorized welding (m) evidence of unauthorized alterations such as drilling, machining, grinding, or other modifications Below-the-Hook Lifting Devices - Reprinted from ASME B Structural and Mechanical Lifting Devices: Inspection Classification (a) Initial Inspection (1) New and reinstalled lifters shall be inspected by a designated person prior to initial use to verify compliance with applicable provisions of this volume. (2) Altered or repaired lifters shall be inspected by a designated person. The inspection may be limited to the provisions affected by the alteration or repair, as determined by a qualified person. (b) Inspection Intervals. Inspection procedure for lifting in regular service is divided into three general classifications based upon the intervals at which inspection should be performed. The intervals, in turn, are dependant upon the critical components of the lifters and degree of their exposure to wear, deterioration, or malfunction. The three general classifications are herein designated as every lift, frequent, and periodic, with respective intervals between inspections as defined below. (1) Every lift inspection. Visual examination by the operator before and during each lift made by the lifter. (2) Frequent inspection. Visual examinations by the operator or other designated persons with records not required. (a) Normal Service - monthly (b) Heavy Service - weekly to monthly (c) Severe Service - daily to weekly (d) Special or infrequent service - as recommended by a qualified person before and after each occurrence. (3) Periodic Inspection. Visual inspection by a qualified person making records apparent external conditions to provide the basis for a continuing evaluation. An external code mark on the lifter is an acceptable identification in lieu of records. (a) Normal service for equipment in place - yearly (b) Heavy Service [as in (a) above, unless external conditions indicate that disassembly should be done to permit detailed inspection] - semiannually (c) Severe service [ as in (b) above] - quarterly (d) Special or infrequent service - as recommended by a qualified person before the first such occurrence and as directed by the qualified person for any subsequent occurrences Every Lift Inspection Items such as the following shall be inspected by operator before and / or during every lift for any indication of damage as specifically indicated, including observations during operation for any damage that might occur when installed (a) surface of the load for debris (b) condition and operation of the controls (c) condition and operation of the indicators and meters when installed

9 Frequent Inspection Items such as the following shall be inspected for damage at intervals as defined in para (b)(2), including observations during operation for any indications of damage that might appear between inspections. A qualified person shall determine whether any indications of damage constitute a hazard or will require more frequent inspection. For all lifters, inspect (a) structural members for deformation, cracks, or excessive wear on any part of the lifter (b) loose or missing guards, fasteners, covers, stops, or nameplates (c) all functional operating mechanisms and automatic hold and release mechanisms for misadjustments interfering with operation Periodic Inspection Complete inspection of the lifter shall be performed at intervals as defined in para (b)(3). Any deficiencies, such as listed below, shall be examined and determination made as to whether they constitute a hazard. These inspections shall include the requirements of para and, in addition, items such as the following: (a) loose bolts or fasteners (b) cracked or worn gears, pulleys, sheaves, sprockets, bearings, chains, and belts (c) excessive wear or friction pads, linkages, and other mechanical parts (d) excessive wear at hoist hooking points and load support clevises or pins Manually Lever Operated Hoists - Reprinted from ASME B Chain Type: Inspection Classification (a) Initial Inspection. Prior to initial use, all new, altered, or modified hoists shall be inspected by a designated person to verify compliance with the applicable provisions of this volume. (b) Inspection Procedures. Inspection procedures for hoists in regular service are divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the critical components of the hoist and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as frequent and periodic, with respective intervals between inspections as defined below. (1) Frequent Inspection. Visual examinations by the operator or other designated person with records not required. (a) normal service monthly (b) heavy service weekly to monthly (c) severe service daily to weekly (d) special or infrequent service as recommended by a qualified person before and after each occurrence (2) Periodic Inspection. Visual inspection by a designated person who makes records of external conditions to provide the basis for a continuing evaluation. An external coded mark on the hoist is an acceptable identification in lieu of records. (A metal stamp mark shall not be made in a highly stressed area.) (a) normal service yearly. (b) heavy service semiannually. If external conditions indicate, disassembly should be done to permit detailed inspection. (c) severe service quarterly. If external conditions indicate, disassembly should be done to permit detailed inspection. (d) special or infrequent service as recommended by a qualified person before the first such occurrence and as directed by the qualified person for any subsequent occurrences Frequent Inspection (a) Frequent inspections shall be performed at intervals defined in para (b)(1) and shall include observations during operation. (b) A designated person shall determine whether conditions found during the inspection constitute a hazard and whether a more detailed inspection is required. (c) The following items shall be inspected: (1) operating mechanisms for proper operation, proper adjustment, and for unusual sounds such as, but not limited to, binding noise of the chain, bearing squeal (2) hooks in accordance with ASME B30.10, frequent inspection (3) hook latches, if used, for proper operation (4) load chain in accordance with para (c) or (c) (5) load chain reeving for compliance with the recommendations of the hoist manufacturer or a qualified person (6) hoist lever for bends, cracks, or other damage (7) damage to the support for the hoist Periodic Inspection (a) Periodic inspections shall be performed at intervals defined in para (b)(2). These inspections may be performed with the hoist at its location, and do not require the hoist to be disassembled. (b) Covers and other items normally supplied to allow inspection of components should be opened or removed for the inspection and then closed or replaced before restoring the hoist to normal operation unless further maintenance is required.

10 10 (c) A designated person shall determine whether conditions found during inspection constitute a hazard and whether disassembly is required. (d) The following items shall be inspected: (1) the items listed in para (2) fasteners for evidence of loosening (3) load blocks, suspension housings, levers, chain attachments, clevises, yokes, suspension bolts, shafts, gears, bearings, pins, rollers, and locking and clamping devices for evidence of wear, corrosion, cracks, and distortion (4) hook retaining nuts or collars, and pins; welds or rivets used to secure the retaining members for evidence of damage (5) load sprockets or idler sprockets for evidence of damage and wear (6) the brake mechanism on friction brake hoists for evidence of worn, glazed, or oil contaminated friction disks; worn pawls, cams, or ratchets; corroded, stretched, or broken pawl springs (7) supporting structure or trolley, if used, for evidence of damage (8) labels, required by para , for legibility and replacement (9) end connections of load chains for evidence of wear, corrosion, cracks, damage, and distortion including over travel restraints (10) the hoist and hoist mounting for evidence of missing items Welded Link Chain Inspection (a) Test the hoist under load in lifting and lowering directions and observe the operation of the chain and sprockets. The chain should feed smoothly into and away from the sprockets. (b) If the chain binds, jumps, or is noisy, first see that it is clean and properly lubricated. If the trouble persists, inspect the chain and mating parts for wear, distortion, or other damage. (c) Examine visually for gouges, nicks, weld spatter, corrosion, and distorted links. Slacken the chain and move the adjacent links to one side to inspect for wear at the contact points. If wear is observed or if stretching is suspected, the chain should be measured according to the hoist manufacturer s instructions. If instructions are not available, proceed as follows. (1) Select an unworn, unstretched length of the chain (e.g., at the slack end). (2) Suspend the chain vertically under tension and, using a caliper-type gage, measure the outside length of any convenient number of links approximately 12 in. (305 mm) to 24 in. (610 mm) overall. (3) Measure the same number of links in the used sections and calculate the percentage increase in length Welded Link Chain Replacement (a) If the used chain exceeds the hoist manufacturer s recommended length (or in the absence of such recommendation, if the used chain is 21 2% longer than the unused chain), replace the chain. Repairing of load chain by welding or any other means shall not be attempted by anyone other than the chain manufacturer. (b) The existence of gouges, nicks, corrosion, weld spatter, or distorted links is sufficient reason for questioning chain safety and considering chain replacement. Safety in this respect depends largely upon the use of good judgment by an appointed or designated person in evaluating the degree of deficiency. (c) Replacement chain shall be the same size, grade, and construction as the original chain furnished by the hoist manufacturer, unless otherwise recommended by the hoist manufacturer due to actual working conditions. (d) Load chain links that pass over the hoist load sprocket on edge (as opposed to those that lie flat in the pockets) shall be installed with the welds away from the center of the sprocket. This precaution is not required on idler sprockets that change the direction but not the tension in the chain. (e) The chain shall be installed without any twist between the hoist and an anchored end on either the load side or slack side. (f) When chain is replaced, inspect the mating parts (sprockets, guides, stripper) for wear and replace, if necessary. (g) Load chain, discarded or new, shall not be used for slings Roller Chain Inspection (a) Test the hoist under load in lifting and lowering directions and observe the operation of the chain and sprockets. The chain should feed smoothly into and away from the sprockets. (b) If the chain binds, jumps, or is noisy, first see that it is clean and properly lubricated. If the trouble persists, inspect the chain in accordance with paras (c) and (d) and inspect mating parts for wear distortion or other damage. (c) Examine visually for gouges, nicks, weld splatter, corrosion, and distortion. (d) Roller chain should first be inspected while it is in the hoist. With the hoist suspended in normal position, apply a light load of approximately 100 lb (46 kg). (1) Check chain for elongation following the hoist manufacturer s instruction. In absence of specific instructions, the chain can be checked by determining the normal pitch and measuring a 12 in. (305 mm)section of chain that normally travels over the load sprocket. Using a caliper-type gage, check the dimension from the edge of one chain pin to the corresponding edge of another pin for the number of pitches per foot. If elongation exceeds 1 4 in. (6.3 mm) in 12 in. (305 mm) the chain shall be replaced. For example, a 3 4 in. (19 mm) pitch chain should measure 12 in. (305 mm) over 16 pitches. Chain shall be rejected if measurement over 16 pitches exceeds in. (311 mm).

11 11 (2) Check chain for twist. The chain shall be replaced if the twist in any 5 ft (1.52 m) section exceeds 15 deg. (3) Check for straightness in plane perpendicular to plane of rollers. A chain that has a bow exceeding 1 4 in. (6.3 mm) in any 5 ft (1.52 m) section shall be replaced. (e) Additional inspection of the chain should be made by removing chain from hoist and cleaning it thoroughly in an acid-free solvent. A check should then be made for any of the following deficiencies: (1) pins turned from their original position (2) rollers that do not run freely with light finger pressure (3) joints that cannot be flexed by easy hand pressure (4) side plates that are spread open (a visual check of the pin head extension at the damaged area, as compared to the pin extension at the free end of the chain, can determine the amount of spread and the condition of the chain) (5) corrosion, pitting, or discoloration of chain (generally indicative of serious impairment) (6) gouges, nicks, or weld spatter Roller Chain Replacement (a) Roller chain shall be replaced if any of the conditions exist as stated in paras (c) and (d). (b) Repairing of roller chain by welding or heating shall not be attempted. (c) The existence of any of the conditions stated in para (d) is reason to question chain safety and for a designated person to give consideration for replacement. Roller chains are subject to hidden wear and deterioration that must be considered. (d) Replacement chain shall be the same size, grade, and construction as the original chain furnished by the hoist manufacturer unless otherwise recommended by the hoist manufacturer due to actual working conditions. (e) When chain is replaced, disassemble and inspect the mating parts (sprockets, guides, stripper) for wear and replace, if necessary. (f) When chain is replaced, it should be reeved in the recommended manner and should operate freely over all load and idler sprockets. All connecting links and chain end fastenings should be inspected and properly secured. Hoist manufacturer s recommendations should be followed on the selection and installation of connecting links. (g) Roller chains, discarded or new, shall not be used for slings. Wire Rope Type: Inspection Classification (a) Initial Inspection. Prior to initial use, all new, altered, or modified hoists shall be inspected by a designated person to verify compliance with the applicable provisions of this volume. (b) Inspection Procedures. Inspection procedures for hoists in regular service are divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the critical components of the hoist and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as frequent and periodic, with respective intervals between inspections as defined below. (1) Frequent Inspection. Visual examinations by the operator or other designated person with records not required. (a) normal service monthly (b) heavy service weekly to monthly (c) severe service daily to weekly (d) special or infrequent service as recommended by a qualified person before and after each occurrence (2) Periodic Inspection. Visual inspection by a designated person who makes records of external conditions to provide the basis for a continuing evaluation. An external coded mark on the hoist is an acceptable identification in lieu of records. (A metal stamp mark shall not be made in a highly stressed area.) (a) normal service yearly. (b) heavy service semiannually. If external conditions indicate, disassembly should be done to permit detailed inspection. (c) severe service quarterly. If external conditions indicate, disassembly should be done to permit detailed inspection. (d) special or infrequent service as recommended by a qualified person before the first such occurrence and as directed by the qualified person for any subsequent occurrences Frequent Inspection (a) Frequent inspections shall be performed at intervals defined in para (b)(1) and shall include observations during operation. (b) A designated person shall determine whether conditions found during the inspection constitute a hazard and whether a more detailed inspection is required. (c) The following items shall be inspected: (1) operating mechanism for proper operation, proper adjustment, and for unusual sounds such as, but not limited to, binding noise of the wire rope, bearing squeal (2) hooks in accordance with ASME B30.10, frequent inspection (3) hook latches, if used, for proper operation (4) wire rope in accordance with para (a)

12 (5) wire rope reeving for compliance with hoist manufacturer s recommendations (6) hoist lever for bends, cracks, or other damage (7) damage to the support for the hoist Periodic Inspection (a) Periodic inspections shall be performed at intervals defined in para (b)(2). These inspections may be performed with the hoist at its location, and do not require the hoist to be disassembled. (b) Covers and other items normally supplied to allow inspection of components should be opened or removed for the inspection and then closed or replaced before restoring the hoist to normal operation unless further maintenance is required. (c) A designated person shall determine whether conditions found during inspection constitute a hazard and whether disassembly is required. (d) The following items shall be inspected: (1) the items listed in para (2) fasteners for evidence of loosening (3) load blocks, suspension housings, levers, chain attachments, clevises, yokes, suspension bolts, shafts, gears, bearings, pins, rollers, and locking and clamping devices for evidence of wear, corrosion, cracks, and distortion (4) hook retaining nuts or collars and pins; welds or rivets used to secure the retaining members for evidence of damage (5) drums and sheaves for evidence of damage and wear (6) the brake mechanism on friction brake hoists for evidence of worn, glazed, or oil contaminated friction disks; worn pawls, cams, or ratchets; corroded, stretched, or broken pawl springs (7) supporting structure or trolley, if used, for evidence of damage (8) label or labels, required by para (d) for legibility and replacement (9) end connections of wire rope for evidence of deterioration (10) hoist rope shall be inspected in accordance with para (b) (11) the hoist and hoist mounting for evidence of missing items Wire Rope Inspection (a) Frequent Inspection (1) Ropes should be visually inspected by the operator or other designated person at the start of each shift. These visual observations should be concerned with discovering gross damage that may be an immediate hazard, such as the following: (a) distortion of the rope such as kinking, crushing, unstranding, birdcaging, main strand displacement, or core protrusion (b) general corrosion (c) broken or cut strands (d) number, distributions, and type of visible broken wires [see paras (b)(1) and (2) for further guidance] (2) When such damage is discovered, the rope shall either be removed from service or given an inspection as detailed in para (b). (b) Periodic Inspection (1) The inspection frequency shall be determined by a qualified person and shall be based on such factors as expected rope life as determined by experience on the particular installation or similar installations; severity of environment; percentage of rated load lifts; frequency rates of operation; and exposure to shock loads. Inspections need not be at equal calendar intervals and should be more frequent as the rope approaches the end of its useful life. (2) Periodic inspections shall be performed by a designated person. This inspection shall cover the entire length of rope. The individual outer wires in the strand of the rope shall be visible to this person Rope Replacement (a) No precise rules can be given for determination of the exact time for rope replacement, since many variable factors are involved. Once a rope reaches any one of the specified removal criteria, it may be allowed to operate to the end of the work shift, based on the judgment of a qualified person. The rope shall be replaced after that work shift, at the end of the day, or at the latest time prior to the equipment being used by the next work shift. (b) Removal criteria for rope replacement shall be as follows: (1) in running ropes, 12 randomly distributed broken wires in one lay or four broken wires in one strand in one lay (2) one outer wire broken at the contact point with the core of the rope that has worked its way out of the rope structure and protrudes or loops out from the rope structure (3) wear of one-third the original diameter of outside individual wires (4) kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structure. Any deterioration resulting in appreciable loss of original strength, such as described below, shall be noted, and determination shall be made as to whether further use of the rope would constitute a hazard:

13 (a) points listed in para (a) (b) reduction of rope diameter below nominal diameter due to loss of core support, internal or external corrosion, or wear of outside wires (c) severely corroded or broken wires at end connections (d) severely corroded, cracked, bent, worn, or improperly applied end connections (5) special care should be taken when inspecting sections of rapid deterioration such as the following: (a) sections in contact with saddles, equalizer sheaves, or other sheaves where rope travel is limited (b) sections of the rope at or near terminal ends where corroded or broken wires may protrude (c) sections subject to reverse bends (d) sections of rope that are normally hidden during visual inspection, such as parts passing over sheaves (6) evidence of heat damage for any cause (7) reductions from nominal diameter greater than those shown below: Rope Diameter Up to 5/16 (8 mm) Over 5/16 to 1/2 (13 mm) 13 Maximum Allowable Reduction from Nominal Diameter 1/64 (0.4 mm) 1/32 (0.8 mm) (c) Broken wire removal criteria cited in this volume apply to wire rope operating on steel sheaves and drums. The user shall contact the sheave and drum or hoist manufacturer, or a qualified person, for broken wire removal criteria for wire ropes operating on sheaves and drums made of material other than steel. (d) Attention shall be given to end connections. Upon development of two broken wires adjacent to a socketed end connection, the rope should be resocketed or replaced. Resocketing shall not be attempted if the resulting rope length will be insufficient for proper operation. (e) Replacement rope and connections shall have a strength rating at least as great as the original rope and connections furnished by the hoist manufacturer. Any deviation from the original size, grade, or construction shall be specified by a rope manufacturer, the hoist manufacturer, or a qualified person. Web Strap Type: Inspection Classification (a) Initial Inspection. Prior to initial use, all new, altered, or modified hoists shall be inspected by a designated person to verify compliance with the applicable provisions of this volume. (b) Inspection Procedures. The inspection procedures for hoists in regular service are divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the critical components of the hoist and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as frequent and periodic, with respective intervals between inspections as defined below. (1) Frequent Inspection. Visual examinations by the operator or other designated person with records not required. (a) normal service monthly (b) heavy service weekly to monthly (c) severe service daily to weekly (d) special or infrequent service as recommended by a qualified person before and after each occurrence (2) Periodic Inspection. Visual inspection by a designated person who makes records of external conditions to provide the basis for a continuing evaluation. An external coded mark on the hoist is an acceptable indication in lieu of records. (A metal stamp mark shall not be made in a highly stressed area.) (a) normal service yearly. (b) heavy service semiannually. If external conditions indicate, disassembly should be done to permit detailed inspection. (c) severe service quarterly. If external conditions indicate, disassembly should be done to permit detailed inspection. (d) special or infrequent service as recommended by a qualified person before the first such occurrence and as directed by the qualified person for any subsequent occurrences Frequent Inspection (a) Frequent inspections shall be performed at intervals defined in para (b)(1) and shall include observations during operation. (b) A designated person shall determine whether conditions found during the inspection constitute a hazard and whether a more detailed inspection is required. (c) The following items shall be inspected: (1) operating mechanisms for proper operation, proper adjustment, and for unusual sounds such as, but not limited to, binding noise of the web strap or bearing squeal. (2) hooks in accordance with ASME B30.10, Frequent Inspection. (3) hook latches, if used, for proper operation.

14 (4) web strap in accordance with para (5) web strap reeving for compliance with the recommendations of the hoist manufacturer or a qualified person. (6) hoist lever for bends, cracks, or other damage. (7) damage to the support for the hoist Periodic Inspection (a) Periodic inspections shall be performed at intervals defined in para (b)(2). These inspections may be performed with the hoist at its location, and do not require the hoist to be disassembled. (b) Covers and other items normally supplied to allow inspection of components should be opened or removed for the inspection and then closed or replaced before restoring the hoist to normal operation unless further maintenance is required. (c) A designated person shall determine whether conditions found during inspection constitute a hazard and whether disassembly is required. (d) The following items shall be inspected: (1) the items listed in para (2) fasteners for evidence of loosening (3) web strap, suspension housings, levers, chain attachments, clevises, yokes, suspension bolts, shafts, gears, bearings, pins, rollers, and locking and clamping devices for evidence of wear, corrosion, cracks, and distortion (4) hook retaining nuts or collars and pins; welds or rivets used to secure the retaining members for evidence of damage (5) load sprockets or idler sprockets (drums) for evidence of damage and wear (6) the brake mechanism on friction brake hoists for evidence of worn, glazed, or oil contaminated friction disks; worn pawls, cams, or ratchets; corroded, stretched, or broken pawl springs (7) supporting structure or trolley, if used, for evidence of damage (8) label or labels, required by para for legibility and replacement (9) end connections of web strap for evidence of deterioration (10) web strap shall be inspected in accordance with para (b) (11) the hoist and hoist mounting for evidence of missing items Web Strap Inspection (a) Frequent Inspection (1) Web straps should be visually inspected by the operator or other designated person at the start of each shift. These visual observations should be concerned with discovering gross damage, such as that listed below, which may be an immediate hazard: (a) melting or charring (b) acid or caustic burns (c) weld spatter (d) broken stitching (e) cuts or tears (f) damaged eyes or fittings (g) abrasive wear (h) knots (b) Periodic Inspection (1) The inspection frequency shall be determined by a qualified person and shall be based on such factors as expected web strap life as determined by experience on the particular installation or similar installations; severity of environment; percentage of rated load lifts; frequency of operation; and exposure to shock loads. Inspections need not be at equal calendar intervals and should be more frequent as the web strap approaches the end of its useful life. (2) Periodic inspections shall be performed by a designated person. This inspection shall cover the entire length of web strap. (3) Special care should be taken when inspecting sections for rapid deterioration, such as the following: (a) sections in contact with saddles, equalizer sheaves, or other sheaves where web strap travel is limited (b) sections of the web strap at or near terminal ends where broken threads or cuts may be evident (c) sections subject to reverse bends (d) sections of web strap that are normally hidden during visual inspection, such as parts passing over sheaves Web Strap Replacement (a) No precise rules can be given for determination of the exact time for the replacement of web strap, since many variable factors are involved. Continued use in this respect depends largely upon good judgment by an appointed or authorized person in evaluating remaining strength in a used web strap after allowance for deterioration disclosed by inspection. Continued web strap operation depends upon this remaining strength. (b) Conditions such as the following shall be reason for questioning continued use of the web strap or increasing the frequency of inspection: