BASIC MECHANICS IN RELATION TO

LIFTING EQUIPMENT; Levers,

Hydraulics, Pulley System,
Forces etc.
FOR REVALIDATION AND
CERTIFICATION EXERCISE FOR
APPROVED PERSONS FOR
INSPECTION OF LIFTING
EQUIPMENT
13 October, 2014

West Africa Ventures Oil and Gas

Free Zone Onne, Rivers State

PRESENTED BY:
EMMANUEL J NNAJI ONWUKA
INTRODUCTION
The natural need to manage loads more than what
ordinary human effort cannot do is the principal
reason for the creation of lifting equipment.
Lifting equipment is a tool that can be used to lift,
suspend, move and position load safely from one
point to the other.
The lifting equipment comprise many accessories
which themselves cannot lift or move a load but can
be used to attach the load to the lifting device.
The basic need to meet in the lifting operation is to
achieve the lift safely.
Presented By: Emmanuel J. Nnaji Onwuka
INTRODUCTION CONT.
 The complexity of machine came as a result of need to
manage heavy loads safely and economically too. This
leads to the three basic issues
 Power (motion driver)
 Strength (structural integrity)
 Balance (stability on the ground)

 For the purpose of this presentation, we are going to

look at the whole system from the basic mechanics
principles.

Presented By: Emmanuel J. Nnaji Onwuka

THE THREE BASIC QUESTIONS
 Can the load be lifted
 Can the lifting equipment lift, hold and position the load
 Can the lifting equipment remain stable while
maneuvering with the load?
 These key issues are what the equipment manufacturers’
consider most before other things and that is what
Engineering designer calculates
 When this equipment is in service, its continued use for
purpose or otherwise is the reason why we are here as
competent inspectors of lifting equipment.

Presented By: Emmanuel J. Nnaji Onwuka

KEY FACTORS INVOLVED IN LIFTING
Recall that lifting equipment developed from the
simple leverage and pulley system.
The leverage governs the stability
The block and tackle governs the hoisting
The common guest of the system is the load
which is a force.
The Hydraulic is a power transmitter.
Therefore, the lifting equipment has to be balanced to
bring the opposing forces into equilibrium at all times
in the course of load handling.

Presented By: Emmanuel J. Nnaji Onwuka

 We give credit to Basic Mechanics principles of
Physics for all the ancient, contemporary and future
innovations in lifting equipment design and indeed
many others.
 In order to appreciate the work we, look at the
relationship between this mechanics and the lifting
equipment.
 On this point we are all welcome to the topic.”BASIC
MECHANICS IN RELATION TO LIFTING EQUIPMENT”.
Areas of concern includes: LEVER, HYDRAULICS,
PULLEY SYSTEM, FORCES, ETC.

Presented By: Emmanuel J. Nnaji Onwuka

LEVER MECHANICS

Presented By: Emmanuel J. Nnaji Onwuka

 THE LEVER MECHANICS
 Definition: A lever is any tool that employs a system
giving advantage to the operator by way of mechanical
advantage. The most basic example of a lever is the use of a
crowbar prising up a heavy weight. This is a system used
not only by humans, but by many lesser animals also.

A lever comprises three fundamental features, the load,

fulcrum and effort. As with the 'law of the lever'
equilibrium is achieved and maintained when the product
of the load multiplied by its distance from the fulcrum is
equal to the product of the effort multiplied by its distance
from the fulcrum.

Presented By: Emmanuel J. Nnaji Onwuka

BASIC LEVER DIAGRAM

LOAD

EFFORT

FULCRUM

Presented By: Emmanuel J. Nnaji Onwuka

BASIC LEVER ILLUSTRATION

Presented By: Emmanuel J. Nnaji Onwuka

CRANE STABILITY
A crane uses
the power of its
hoisting
apparatus to
lift a load. This
includes the
motor, drum,
wire rope, and
block sheaves.

Presented By: Emmanuel J. Nnaji Onwuka

CRANE LEVERAGE

Presented By: Emmanuel J. Nnaji Onwuka

CRANE VS LOAD LEVERAGE

The actual
stability (tipping
resistance) of a
crane is based on
the lever
principle. See
illustration

Presented By: Emmanuel J. Nnaji Onwuka

CRANE LEVERAGE DECREASING

Presented By: Emmanuel J. Nnaji Onwuka

TIPPING AXIS OVER THE SIDE

Due to the
configuration of a
crawler crane with its
center of gravity (C of
G) almost at the center
pin, the C of G changes
very little as the crane
rotates.

Presented By: Emmanuel J. Nnaji Onwuka

TIPPING AXIS OVER THE FRONT
The tipping axis of a
crawler crane is at the
center of its tract on a
side lift. The leverage
can be increase on
some cranes by
extending the tracks.
The tipping axis is
between the diameter
of the drive or idler
sprocket when lifting
over the front or rear

Presented By: Emmanuel J. Nnaji Onwuka

TIPPING AXIS OVER THE REAR
On most rubber
tired mobile
cranes, the C of G
of the unit
dramatically as
the boom swings
from the rear, to
the side, to over
the front.
On a lift over the
rear the combined
C of G is well back
of the tipping axis,
see illustration

Presented By: Emmanuel J. Nnaji Onwuka

 TIPPING AXIS OVER THE SIDE

When the boom

swings over the
side the C of G
shifts closer to
the tipping axis,
see illustration

Presented By: Emmanuel J. Nnaji Onwuka

TIPPING AXIS OVER THE FRONT

Swinging the boom over

the front shifts the C of G
dangerously close to the
tipping axis, see
illustration.
Note: When lifting over
the front, the cab and
truck front drive train
are hanging over the
front outriggers thereby
adding leverage to that
caused by the load.

Presented By: Emmanuel J. Nnaji Onwuka

LOWER BOOM AND LOSE STABILITY
As crane stability is
base on the
leverage principle,
the rule that would
apply for crane-
load balance is
equal leverage;
how-ever if the
crane is to lift the
load without
tipping and with a
suitable safety
margin, the crane
leverage must be
greater than the
load leverage.
Presented By: Emmanuel J. Nnaji Onwuka
CRANE STABILITY FACTOR
Crane operates on safety factor
to avoid tipping. The
maximum rated capacity of a
crane is a percentage of the
load that would tip the crane.

CAPACITY CHART RATING

BASED ON PERCENTAGE OF TIPPING
TYPE OF CRANE PERCENTAGE
LOCOMOTIVE 85%
CRAWLERS 75%
MOBILES ON ROUGH TERRAIN
On outriggers 85%
On tires 75%
COMMERCIAL BOOM TRUCKS
On stabilizers 85%

Check your crane – above percentages not used

by manufacturers

ANSI B 30.5 & CSA Z150

Presented By: Emmanuel J. Nnaji Onwuka

Mechanical Advantage: In fig.1 the effort required to
keep the lever in equilibrium is less than the load as it
is a further distance from the fulcrum. The greater the
difference between the force of the effort and the
force of the load means the greater the mechanical
advantage. More simply the Mechanical Advantage
(MA) can be calculated as follows;

MA = load / effort.

Presented By: Emmanuel J. Nnaji Onwuka

Velocity Ratio: There is no such thing as a free
lunch. So the saying goes. This is certainly true
of the use of levers. Although the effort to
stabilise the load` is less than the load, to move
the load the effort will also have to move, the
ratio of distance moved by the effort to the load
is in reverse proportion to the magnitude of the
effort to the load

Presented By: Emmanuel J. Nnaji Onwuka

 radius RADIUS

Distance
moved by
load
Distance
moved by load

Example 1. Fig.2 A load of 50 N can be moved by an

effort of 10N. Calculate the MA.
MA = Load = 50 =5
Effort 10

Velocity Ratio: = distance moved by effort

Distance moved by load

Presented By: Emmanuel J. Nnaji Onwuka

Example 2. The load is moved through 95mm
when the effort moves through 760mm. Calculate the
velocity ratio.
V.R. = 760 =8
95
Note: The V.R. of a lever can also be calculated by:
V.R. = RADIUS
Radius

The efficiency of the machine is measured by:

Efficiency = MA X 100%
V.R.
Thus combining example 1 and 2

Efficiency = (5 X 100)/8 = 62.5%

Presented By: Emmanuel J. Nnaji Onwuka
No machine can be 100% efficient. From the examples above:
Work done by the effort = force x distance moved
= 10N x 0.76m
= 7.6 joules
Work done by the load = force x distance moved
= 50N x 0.095M
= 4.75joules

work done by load X 100%

Efficiency =
Work done by effort
= 4.75 X 100%
7.6 = 62.5%

or: energy out of the machine

energy put into the machine

Presented By: Emmanuel J. Nnaji Onwuka

PULLEY MECHANICS

Presented By: Emmanuel J. Nnaji Onwuka

INTRODUCTION

Presented By: Emmanuel J. Nnaji Onwuka

Parts of a Pulley System

Direction of Force
Notice that the pulleys change the
direction of the applied force.
Presented By: Emmanuel J. Nnaji Onwuka
Types of Pulley.
1. A fixed pulley

A ski lift operates on a fixed pulley system

Presented By: Emmanuel J. Nnaji Onwuka

2. A moveable pulley - rises and
falls with the load being moved.

Moveable pulley

Presented By: Emmanuel J. Nnaji Onwuka

 3. A block and tackle - Consists
of two or more pulleys (fixed and
moveable).

Block and tackle

Presented By: Emmanuel J. Nnaji Onwuka
 The Pulley Advantage

In this simple pulley system,

the force is equal to the load,
so the Mechanical Advantage is 1:1 or 1.

10 Kg = 100 N

The Mechanical Advantage is calculated like so:

Mechanical Advantage = Load / Effort = 100 N / 100 N
Mechanical Advantage = 1:1 or 1
 The Pulley Advantage

Each side of the rope carries half the load.

Therefore, the force required by the person to
keep the load in equilibrium is also half the load.

This system has a

Mechanical Advantage of 2:1 or 2.

10 Kg = 100 N

The Mechanical Advantage is calculated like so:

Mechanical Advantage = Load / Effort = 100 N / 50 N
Mechanical Advantage = 2:1 or 2
The Pulley Advantage

This system has a

Mechanical Advantage of 4:1 or 4.

10 Kg = 100 N

The Mechanical Advantage is calculated like so:

Mechanical Advantage = Load / Effort = 100 N / 25 N
Mechanical Advantage = 4:1 or 4
The Pulley Advantage
This system has a
Mechanical Advantage of 4:1 or 4.

200 Kg = 2000 N

The Mechanical Advantage is calculated like so:

Mechanical Advantage = Load / Effort = 2000 N / 500 N
Mechanical Advantage = 4:1 or 4
 Pulley drives:

Using pulleys to transmit motion and force:

Pulleys and Belts Toothed Belt and Pulleys

Presented By: Emmanuel J. Nnaji Onwuka

 Pulley drive calculations:
Driver 40 mm Dia.
Driven 70 mm Dia.
280 rev/min
? rev/min

Driven will rotate slower than the driver.

Calculation: -
Diameter of Driver pulley 40
Speed ratio = =
Diameter of Driven pulley 70

40
Speed of Driven pulley = 280 x = 160 rev/min
70

How could you change the direction of rotation of the driven pulley ?

Presented By: Emmanuel J. Nnaji Onwuka

PULLEY IN CRANES
Blocks are used when moving heavy objects weighing
more than the safe working load of a single wire rope.
The sheaves transmit the load imposed by the wire
rope to the center pin, then to the side straps and
connections. Crane blocks have heavy weights on the
sides of the blocks to help downhaul the hook when
unloaded, as indicated in illustration below.
Note: some cranes may have proprietary parts
and components that can only be replaced by the
crane manufacturer.

Presented By: Emmanuel J. Nnaji Onwuka

CRANE BLOCK
Note: Wire rope manufacturers
indicate the efficiency, or wire
rope strength decreases as it
passes over sheaves. Any
capacity calculations with wire
rope passing over a sheave
should be reduced by a
minimum 5%.
The smaller the sheave, the
higher the inefficiency. A one
inch IWRC rope rated at 44.9
tons should be reduced to 42.6
tons. The reduction is only
calculated once, not
compounded on multisheave
blocks.

Presented By: Emmanuel J. Nnaji Onwuka

BLOCK MECHANICAL ADVANTAGE
The mechanical advantage of a machine is the amount by which the
machine multiplies the force applied to move a load. Here, the machine is
a pulley or a combination of pulleys forming a block and tackle system.
Usually this system is used to lift, but it can also be used to move a load
laterally across a floor.

The top (fixed) sheaves on the block have no other function than to
change the direction of the rope. The sheave on the bottom (travelling)
block will create a mechanical advantage 0f 2:1 for each sheave.

Calculating Mechanical Advantage:

Count the number of lines supporting the load, with the exception of the
lead line when it comes down over the top block. The lead line pulling
down is not counted for mechanical advantage.

Presented By: Emmanuel J. Nnaji Onwuka

BLOCK MECHANICAL ADVANTAGE CONTD

If the lead line

comes up to the
winch from the
travelling block it
will be counted as
a supporting line
and included in
the mechanical
advantage

Presented By: Emmanuel J. Nnaji Onwuka

BLOCK SPEED AND DISTANCE
 The speed of the travelling block and the distance of load
travel is determined by the mechanical advantage. The
speed of the travelling block and the load is calculated by
dividing the lead line speed by the number of parts of line,
or the mechanical advantage (M/A). Or in other words,
using a 5 to 1 M/A, the lead line will travel five feet for every
foot the load is lifted, and it will travel five times as fast.

 The amount of wire rope needed for the system is

determined by measuring the top to travelling block
distance and multiplying by the number of parts of line,
plus enough wire rope to go to the winch and have at least
several full wraps on the winch drum.

Presented By: Emmanuel J. Nnaji Onwuka

BLOCK FRICTION
 When the load moves, part of the lifting force is lost
due to friction in the turning of the sheaves, and the
wire rope bending over the sheaves. Therefore the lead
line pull must be increased to make up for this loss.

 This relationship between a rope sheave and friction is

called efficiency, and is usually expressed in terms of
percent. Each type of sheave has a different friction
percentage, usually based upon the type of bearings in
the sheave. The extra load added by friction is
calculated progressively on a line to line, sheave-to-
sheave basis (see illustration below and the example
which follows).
Presented By: Emmanuel J. Nnaji Onwuka
Presented By: Emmanuel J. Nnaji Onwuka
BLOCK FRICTION CONTD
Load = 60,000 lbs or 30 tons with a 6 part line.
Static load on each line equals:
60,000 / 6 = 10,000 lbs load on each line
Roller bearing sheaves used (97% efficient-approximately 3%
efficiency loss)
Friction Calculation:
Line #1 (becket line) 10,000 lbs
Line #2 10,000 x 1.03 = 10,300 lbs
Line #3 10,300 x 1.03 = 10,609 lbs
Line #4 10,609 x 1.03 = 10,927 lbs
Line #5 10,927 x 1.03 = 11,255 lbs
Line #6 11,255 x 1.03 = 11,593 lbs
Lead line pull = 11,593 x 1.03 = 11,941 lbs
The lead line pull would be 11, 941 lbs.

Presented By: Emmanuel J. Nnaji Onwuka

BLOCK FRICTION RATIO
Table #1 shows the number of parts of line and the efficiency of
three types of sheaves. It includes ratio charts for fiber rope blocks
at 10% friction, wire rope bronze bushing sheaves at 5% friction,
and wire rope roller bearing sheaves at 3% friction.

Three types of calculations can be made using the block friction

ratio table, these are:
1. The number of wire, or fiber rope parts of line required to
make a lift.
2. Determine the maximum load that can be lifted with a given
rigging arrangement.
3. Determine the lead line pull when the load weight and number
of parts of line are established or the rope size is known.
Three examples of these calculations are shown below.

Presented By: Emmanuel J. Nnaji Onwuka

 Ratio factors To Account For Friction
Loads
# of Bronze Bronze Bronze
Parts Bushed Bushed Bushed
of Fibre Fibre Fibre
Lines Rope 10% Rope Rope 3%
5%
1 .91 .95 .97
2 1.65 1.82 1.89
3 2.26 2.59 2.75
4 2.74 3.28 3.54
5 3.11 3.91 4.31
6 3.39 4.48 5.00
7 3.61 4.96 5.69
8 3.74 5.41 6.30
9 5.81 6.87
10 6.13 7.41
11 6.43 7.91
12 6.67 8.39
Table #2 – Wire Rope Nominal Strengths
13 6.88 8.84
14 7.07 9.27
Table #3 – Wire Rope Working Load Limits (SWL)
15 7.21 9.62
16 7.34 9.94
17 7.42 1.30
18 7.48 10.59
19 7.51 10.80
20 7.55 11.05

Table #1 - Block Friction Ratio Table

1. Determine Number of Parts of Line
Required:
Determine the WLL (SWL) of the wire rope by chart or rule of thumb.
The rule of thumb formula is:
Diameter squared x 8 = WLL (SWL).
Determine the weight of the load.
Load weight / WLL = R (ratio).
Find ratio in table above
The number of parts of line is indicated opposite the applicable ratio number.

Example One – Number of Parts of Line:

Size of wire rope = 1 ¼ inch
Load weight = 75 tons
Type of sheaves = roller bearing
WLL (SWL) of 1 ¼ inch rope
= 1.25 x 1.25 x 8 = 12.5 tons
Total weight of load: 75 tons
75 tons / 12.5 = 6 (ratio)

From the column under Roller Bearing wire rope 3%, we read 6.30 as the next highest
number over the calculated answer of 6. The first column indicates 8 parts of line.

Presented By: Emmanuel J. Nnaji Onwuka

2. Determine Maximum Load to be Lifted:
The number of parts of line to be used.
Type of sheaves: 3% for roller bearings, 5% for bronze bushing.
The WLL or safe working load of the wire rope to be used or the maximum lead line pull.
The rule of thumb formula = diameter squared x 8 = WLL (SWL)
Use the ratio from the table #33 opposite the number of parts of line.
Calculate the maximum WLL (SWL) of the wire rope or the lead line pull x the ratio of the
maximum load.

Example Two – Maximum Load:

14 parts of line roller bearing sheaves = 3%
¾ inch wire rope
Roller bearing sheaves = 3% loss due to friction.
¾ inch wire rope = .75 x .75 x 8 = 4.5 tons WLL (SWL)
Chart ratio opposite 14 parts of line = 9.27 (table #33).
To calculate the maximum load:
WLL x ratio = load
4.5 x 9.27 = 41.715 or 42 ton maximum load.

Presented By: Emmanuel J. Nnaji Onwuka

3. Calculation to determine the lead line pull and wire rope
diameter needed when the load weight +and number of parts of
line are established.
The type of sheave: 3% for roller bearings, 5% for bronze bushings.
The total weight of the load including lifting equipment.
The number of parts of line to be used.
Calculate the line pull by dividing the load weight by the ratio
(opposite the correct number of parts of line from table above).
Load weight / ratio = lead line pull
Calculate the size of wire rope needed, with a design factor of five
from tables #2 and #3,

Presented By: Emmanuel J. Nnaji Onwuka

Example Three – Lead Line Pull & Wire
Rope Diameter:
Bronze bushed sheaves = 5%
Load weight = 25 tons
Parts of line = 8
Bronze bushed sheave = 5%
Weight of the load = 25 tons
Parts of line to be used = 8
Chart Ratio (opposite 8 parts on table #1) = 5.41
Calculate the lead line pull
= 25 tons / 5.41 ratio = 4.62 tons.
The lead line pull of 4.62 tons x 5 (design factor) = 23.1 tons of ultimate strength
required.
Calculate the size of wire rope needed:
IWRC improved plow with a design factor of 5; to the next highest number = ¾
inch.
From table #2, ¾ inch = 25.6 tons (ultimate strength), minus 5% = 24.3 tons.
Presented By: Emmanuel J. Nnaji Onwuka
SNATCH BLOCKS
Snatch blocks are used to change the pulling direction of a wire
rope. The side opens to allow positioning of the rope without
having to feed it through the block. See illustration

Presented By: Emmanuel J. Nnaji Onwuka

SNATCH BLOCKS CONTD
The load on the snatch block varies with the angle
between the lead and load lines. When both the lead
and load lines are parallel, the load on the block hook is
double the weight of the load, plus friction when the
load is moving. As the angle opens up, the load on the
hook is reduced. To determine the load on a block,
multiply the pull on the lead line by the applicable factor
from table #4.

Presented By: Emmanuel J. Nnaji Onwuka

 Snatch Block Loading

Note: on a straight vertical pull

(illustration #A), the block rigging
must hold double the load weight.
Table #4 – Factors for Snatch Block Loading

Presented By: Emmanuel J. Nnaji Onwuka

SNATCH BLOCK LOAD EXAMPLE
Illustration below shows a 10,000 pound load being lifted using
four snatch blocks.
All wire rope changing direction from a sheave loses efficiency to
some degree (more pull required).
The efficiency loss depends on the wire rope to sheave size ratio
(D/d), the angle of pull on the sheave (illustration #111), and the
type of sheave.
A snatch block with a bronze bushing loses approximately 5% on a
0 degree pull ((illustration #111A).
In the example shown in illustration #112 sheave A is base on a 5%
(1.05) loss, sheave B at 3% (1.03), and 2% (1.02) for sheaves C and D.
sheaves C, C and D have less efficiency loss because the pull angles
are more open.
The approximate progressive line pull and sheave pull is:

Presented By: Emmanuel J. Nnaji Onwuka

SNATCH BLOCK LOAD EXAMPLE

Presented By: Emmanuel J. Nnaji Onwuka

FORCES (LOAD STRESS)

Presented By: Emmanuel J. Nnaji Onwuka

INTRODUCTION

Presented By: Emmanuel J. Nnaji Onwuka

LOAD SHAPE FACTORS
Actual crane capacities
are based on three basic
factors:
 Weight of the machine
 Stability
 Strength of
components

Presented By: Emmanuel J. Nnaji Onwuka

LOAD SHAPE FACTORS CONTD
 Additional factors enter the picture to affect the lifting and
positioning of a load. The primary one is the actual load
weight, which include the rigging equipment, the crane
block and it wire rope. Three other major contributions are
the shape and dimension of the load, the height to which it
must be raised, and the distance out from the crane
(radius).
 The capacity limitation of the boom must be determined.
Know the length and capacity in different operating angle
and radii. For example illustration below shows a large
dimension load and its limited lift height due to a rather
high boom angles.
 To lift the load higher, the boom angle must be lowered,
which increases the operation load radius. The longer
radius results in less crane capacity and an increased load
stress on its components.
Presented By: Emmanuel J. Nnaji Onwuka
Lower Boom Angle Required to Lift Bulky Load

Presented By: Emmanuel J. Nnaji Onwuka

LOAD SHAPE & LIFT RADIUS
The load radius is the horizontal distance measured
from the rotation center of the crane (mounting pin)
to the load hook, while the boom is under load.
The load radius will increase when the load is lifted
off the ground due to pendant line stretch, and/or
deflection of the boom and machine. See
illustration below

Presented By: Emmanuel J. Nnaji Onwuka

Presented By: Emmanuel J. Nnaji Onwuka
LOAD SHAPE & LIFT RADIUS
Boom movement is more extreme than machine sitting on its
tires, due to deflection of the rubber.
On critical lifts the radius should be re-measure after the load
clears the ground. Recheck the crane load chart as the
increased radius might put the crane into an unsafe lift
condition.

Strength vs Stability
It is important to know the difference between the rated
capacity of cranes in regards to strength and stability.
Strength means that structural components of the crane
probably break when overloaded (rather than tip). Stability
means the crane will tip when overloaded.
Presented By: Emmanuel J. Nnaji Onwuka
STRUCTURAL FAILURE
A structural failure does not necessarily mean an immediate
fracture. Crane that have been overloaded on previous lifts have
had catastrophic structural failure on normal, safe lifts. Some of
the more common failure points are shown in the illustration

Presented By: Emmanuel J. Nnaji Onwuka

BOOM STRENGTH AND WEAKNESS
A crane boom is at its
strongest position in a
near vertical lift. The
compression on the
boom does not cause it
to bend until it is at a
lower angle. See
illustration

Presented By: Emmanuel J. Nnaji Onwuka

BOOM STRENGTH AND WEAKNESS CONTD
When a conventional
lattice boom (or jib)
is lowered it has
increase sag with
more pull on the
supporting pendant
lines. The capacity is
also lowered
considerably, see
illustration

Presented By: Emmanuel J. Nnaji Onwuka

LATTICE BOOM
Boom compression is a major
cause of failure. As the boom
sack the lines of compression
is between the boom tips and
the foot pin. The boom fails
when it cannot take the
compression factor. See
illustration.
Many cranes with extremely
long booms often need
assistance by another crane to
lift the boom off the ground,
the pendant line pull is too
great, and when combine with
boom sag can result in boom
failure.

Presented By: Emmanuel J. Nnaji Onwuka

HYDRAULIC BOOMS
When a hydraulic crane boom is lower to a dangerous point, the
boom tips will bend due to the load leverage. This problem is not
as common at a higher lifting angle as much as the boom load is
supported by the hydraulic boom cylinders. See illustration

Presented By: Emmanuel J. Nnaji Onwuka

SWING AREA PROTECTION
The area around the hoisting operation must be block
off to maintain safety for pedestrians or other nearby
workers. See illustration below
Either rope the area off or use barricades to prevent
access to the swing area of the crane counterweight
and/or the load, depending upon the amount of swing
the crane has to make during the lifting and lowering
procedure.
A clear minimum distance of 2 feet must be maintained
between any building or structure and the closest point
of the crane counterweight during the swing.
Presented By: Emmanuel J. Nnaji Onwuka
Swing Area Protection

Presented By: Emmanuel J. Nnaji Onwuka

ACTUAL VS EFFECTIVE LOAD WEIGHT
Under normal condition anything hanging below is
considered load. When the main load block is being use for
hoisting, and the jib is erected, the effective weight of the jib
may be calculated higher than it actual weight.

This can apply to either lattice or hydraulic booms (see

illustration below). Crane manufacturers use different
methods of calculating the jib weight.
When the main block is being used and the jib is stowed
on the boom its effective weight may be less than is
actual weight. Check the load chart data carefully

Presented By: Emmanuel J. Nnaji Onwuka

Effective vs Actual Jib Weights

Presented By: Emmanuel J. Nnaji Onwuka

LOAD ON BOOM
 Every crane has specific rules for its boom and jib
makeup; however it can be safely assumed that
everything under the boom tip is load.

 This will include the object been lifted, slings and

any rigging components, the hook and hoist block,
and the hoist wire rope below the boom tip (on
most cranes).

Presented By: Emmanuel J. Nnaji Onwuka

LOAD ON BOOM CONTD
 If the jib is erected, it is considered part of the
load, as well as the jib gantry and jib pendants. The
headache ball and hook are also included, as well
as the jib line (on most cranes). See illustration
below. The crane manual and load charts must be
followed closely as some types of cranes will
double the jib weight as part of the load. For
example a 2200 lb. (1000 kg.) jib could be a 4400
lb. (2000 kg.) deduction.

Presented By: Emmanuel J. Nnaji Onwuka

Load on Boom with Jib

Presented By: Emmanuel J. Nnaji Onwuka

LOAD ON JIB
 The load on the jib will be the weight hanging below
the jib tip. This will be actual load, the slings and
rigging components, the headache ball and hook, plus
the jib line (on most cranes).
 The main load block and hook, as well as the main
load line is included as load on most jib calculations.
It must be emphasized that the crane
manufacturers manual and load chart data must be
studied to obtain the specific load details.

Presented By: Emmanuel J. Nnaji Onwuka

Load on Jib

Presented By: Emmanuel J. Nnaji Onwuka

NET AND GROSS LOAD
Two terms are used
concerning the load
being lifted by a crane.
Net load is the weight
of the object being
lifted. Gross load is the
net load plus all rigging
components, hooks,
blocks wire rope, etc.
Gross load is the
number used when
checking the load
charts. See illustration

Presented By: Emmanuel J. Nnaji Onwuka

NET AND GROSS CAPACITY
Two terms are also used
concerning crane
capacity. Gross capacity
‘is the net capacity plus
all attachments, rigging
components, blocks,
hooks, etc.
Net capacity is the
load weight the crane
can lift safely. Gross
capacity is the number
shown on the crane
load chart. See
illustration

Presented By: Emmanuel J. Nnaji Onwuka

STATIC AND DYNAMIC LOAD
 When the load in a crane is suspended in a non-
moving situation it is call the static load.
 When the load begins to move, extra stress is imposed
on the crane. This could be cause by hoisting, lowering
and stopping or rapid swing causing the load radius to
increase. A sudden lift or stop is called impact loading
and should be avoided, as it can easily increase the
load by up to 30% or more. Extreme impact loading
can amount to 100% or more.
 See illustration below for an example of a static
dynamic load.
Presented By: Emmanuel J. Nnaji Onwuka
Static and Dynamic Load

Presented By: Emmanuel J. Nnaji Onwuka

 LOAD CHARTS
 In most discipline where prediction and of out come
depends largely on variable constants, there must be
value charts based on statistical or empirical analysis
 So in lifting equipment load charts are the sort of
compass for safe navigation of the load using a given
lifting appliance.
 Proper understanding and wise adherence to the
charts is a prerequisite for safe use.
 It deemed fit to recap on it here and now.

Presented By: Emmanuel J. Nnaji Onwuka

LOAD CHARTS VS LOAD INDICATORS
Necessity of load charts
 The load chats shows the maximum capacity of
that specific crane under every permissible
configuration. The ability to interpret this chat
correctly is critical for those planning a lift, and to
safe operation of the crane. Crane manufacturers
place the capacity chats in readily accessible
locations in the crane cab. They should be
attached and not removed.

Presented By: Emmanuel J. Nnaji Onwuka

Load Charts vs Load Indicators
 Modern technology, specifically load moment
indicators, and capacity limiters have taken away some
of the old trial and error practices. However, accidents
happen, almost always for reasons that should have
been avoided. Any operator relying on guesswork and
a sign of the crane going light (beginning to tip
slightly) to warn of overload is playing a dangerous
game.
 Many modern cranes will be overloaded before there is
any indication of tipping. The electronic operator aids
must be tested every day to ensure their accuracy. If
there is any doubt, the crane manufactures load chart
information will prevail.
Presented By: Emmanuel J. Nnaji Onwuka
Note: it is a conflict with the manufacturers’ guidelines
and a violation of the some standards (ANSI) to use a
load indicator to weigh a load.
 Do not use signs of tipping to indicate capacity limits.
 Some cranes are overloaded before any sign of tipping.
 Cranes at maximum lift configuration will probably fail
structurally before there is any sign of tipping.
 An operator may not notice the point when a crane goes
 From stable to unstable.
 When a crane begins to tip it may be too late to recover,
even by a quick release of the load.
 A crane is rated at its maximum capacity load ONLY with
its shortest boom section, and lifting at the minimum
radius.

Presented By: Emmanuel J. Nnaji Onwuka

LOAD CHART INFORMATION
All crane manufacturers have different capacity charts for
each of their cranes, but they all include similar information:
 Type of crane base.
 Quadrant of operation.
 Length of boom.
 Angle of boom
 Load radius.
Subtract from gross capacity for additional equipment (jib,
rigging, etc.) two sample load charts are shown in tables
below

Presented By: Emmanuel J. Nnaji Onwuka

Presented By: Emmanuel J. Nnaji Onwuka
LOAD CHART INFORMATION
Typical capacity chart nomenclature includes the following:

Boom length: The measurement from center of boom

hinge pin to center of sheave pin.
Operating radius: The horizontal distance from rotation axis
to center of load block with the load
suspended.
Boom angle: The angle between horizontal and
centerline of boom. This indicates operating
radius. Operating radius governs capacity.
Maximum capacity: Free over side and rear (outriggers not
extended).
Maximum capacity: outriggers extended and set over side and
rear.
Boom point elevation: The distance from ground to center of the
boom point shaft
Presented By: Emmanuel J. Nnaji Onwuka
CHART CONFIGURATIONS
The three basic crane chart configurations are:
 Boom extension and /or jib not installed.
 Lifting from main load line but with boom extension
and/or jib installed.
 Load lifted from boom extension or jib.
Some cranes can have different styles of boom tops, such as
open throat, hammerhead, or light tapered top. Each styles of
top have its own capacity chart. Some crane models use
different numbered booms. The boom number listed on the
capacity chart must correspond to the boom number on the
crane. The amount of counterweight on the crane must
match the specifications in the load chart.
Presented By: Emmanuel J. Nnaji Onwuka
LOAD CHART STRENGTH VS STABILITY
The load numbers in the lower section of most
capacity charts (indicating the lesser lifting
capacities) are based on the crane stability or
tipping. The load numbers in the upper section of
the chart indicate capacities based on structural
strength. To indicate the difference, the upper
numbers may be shaded, divided by a dark line, or
shown with asterisks. These upper chart numbers
mean a crane component will break before there is
any sign of the crane tipping. See illustration below
for examples.

Presented By: Emmanuel J. Nnaji Onwuka

Presented By: Emmanuel J. Nnaji Onwuka
INTERPRETING THE LOAD CHARTS
Load radius, boom length and boom angle are
three critical load chart factors. When
calculating capacity from the chart, and any of
this three do not match the actual crane set up,
then the capacity numbers for a longer radius, a
longer boom length, or a lower boom angle on
the load chart must be used. It is not permitted
to guess or mathematically calculate in-between
(interpolated) chart values. The following text
and illustration explains this more clearly.

Presented By: Emmanuel J. Nnaji Onwuka

RADIUS BETWEEN CHART VALUES
Frequently the measured load radius will fall
between two numbers shown on the load chart.
When this occurs, the chart radius number used
must be the higher number (longer radius-less
capacity). In the illustration below, the crane has an
80 foot boom, and is lifting at an off-the-ground
radius of 38 feet. The chart (page301) indicates a
load rating of 67,000 pounds at a 35 foot radius, and
a load rating of 54,300 at a 40 foot radius. With a
measured distance of 38 feet, the 40 foot rating of
54,300 must be used.
Presented By: Emmanuel J. Nnaji Onwuka
BOOM LENGTH BETWEEN VALUES
 Due to the extension of hydraulic booms, the boom
length will often not march the numbers shown in the
boom length chart. When this occurs, the next highest
boom length number (longer boom-less capacity)
must be used. In illustration #288, the crane is lifting
with an 85 foot boom.

 The chart indicates that an 80 foot boom, at a 50 foot

radius, has a rating of 38,900 pounds. A 90 foot boom
at a 50 foot radius is rated at 38,600. The 90 foot rating
of 38,600 must be used.

Presented By: Emmanuel J. Nnaji Onwuka

BOOM ANGLE BETWEEN VALUES
 If the boom angle indicator shows an angle not
matching the load chart, the angle value used
(lower angle-less capacity) must be the next lowest
number. In illustration below, the crane has an 80
foot boom and the angle indicator shows 59
degrees.
 The chart shows a rating of 38,900 pounds at 55
degree, and 54,300 at 63 degrees. The lower angle
of 55 degrees with the 38,900 rating must be used.

Presented By: Emmanuel J. Nnaji Onwuka

Radius Between Chart Values Boom Length Between Chart Values

Presented By: Emmanuel J. Nnaji Onwuka

Boom Angle Between Chart Values
Presented By: Emmanuel J. Nnaji Onwuka
BASIC HYDRAULIC MECHANICS

Presented By: Emmanuel J. Nnaji Onwuka

HYDRAULICS AS FORCE TRANSMITTER
 Hydraulic transmits power to the mechanical links
whose articulated movements help to raise or lower
structures of lifting machines .
 The action of hydraulic in the system is like that of the
blood in the human body which supplies the strength
to the body .
 Its circulation through the circuitry and its pump
arrangement very similar to that of human
 The use of hydraulic help in having more compct and
yet very powerful lifting equipment

Presented By: Emmanuel J. Nnaji Onwuka

 HYDRAULIC MECHANISM
 How the hydraulic function is controlled
 Hydraulic Schematics
 The outlay of the piping of the complete circuitry of the
hydraulic in system.
 It shows the pathways to the action points and return path
of the hydraulic to the tank. In order to organize the
various actions desired of the equipment, there has to be
ways of sequentially directing the flow of hydraulic to the
various points. In order to achieve this come the need for
the valves which function as substations or depots from
where each action point that is connected to the valve
receives hydraulic supply.
Presented By: Emmanuel J. Nnaji Onwuka
Presented By: Emmanuel J. Nnaji Onwuka
 On the valves are gate controls or lever which opens
and or shuts down the flow of hydraulic into an action
point. The compression of the hydraulic within the
closed air tight system creates pressure within the
circuit and the pressure is monitored by a pressure
gauge. It is this pressure created by the compression of
the hydraulic oil within the barrel that pushes the
piston in or out and sustains in that position for as
long as it serves purpose.

Presented By: Emmanuel J. Nnaji Onwuka

3 POSITION 4 PORT HAND OPERATED VALVE CIRCUIT

Presented By: Emmanuel J. Nnaji Onwuka

UNDERSTANDING HOW HYDRAULIC WORKS

Presented By: Emmanuel J. Nnaji Onwuka

HOW THE PUMP AND MAIN RV WORKS

Presented By: Emmanuel J. Nnaji Onwuka

 As is always the case, there must be a way of relieving the
pressure when it gets beyond the bearing capacity of the closed
system otherwise there’ll be rupture which will cause energy lose,
failure of load and attendant spill of hydraulic and maybe
catastrophic free fall of lifting load.
 This brings in the need for pressure release valve. Unlike the
release valve installed in gas air tanks that releases into the air,
this case is different in the sense that the hydraulic need not be
released outside the system rather be released back into the tank
for continued circulation.
 The release valve not only prevent rupture of the piping but also
and more importantly protects the hydraulic pump from the back
pressure of the returning oil from the action point.

Presented By: Emmanuel J. Nnaji Onwuka

DOUBLE ACTING CYLINDER SCHEMATICS

Presented By: Emmanuel J. Nnaji Onwuka

A THREE POSITION 4 PORT VALVE SCHEMATICS

Presented By: Emmanuel J. Nnaji Onwuka