Lifting Africa Jul / Aug 2015

Lifting Africa

The official magazine for LEEASA (Lifting Equipment Engineering of South Africa) and CMA (Crane Manufacturers Association of SA)

July/Aug 2015

Driven Machinery Regulations 18 Metal Fatigue on Overhead Cranes Chain Gang Golf day

Lifting Africa - July/August 2015

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Lifting Africa - July/August 2015

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Lifting

Contents

Africa

July/August 15

ASSOCIATION NEWS

From the Chairman’s Desk

PERSONALITY PROFILE Doug Poole Honorary Golf Day

5 6 7

CMA NEWS Defragmenting the Industry

8

COVER STORY “Toco - Lifting New heights�

HEALTH & SAFETY

Top 10 Safety Tips for Powered Access Operation 10 Good Tips for Mobile Crane Operations

12 15 37

INSPECTION & TRAINING

Chain Blocks & Lever Hoists Operation, Safe Use & Inspection Course

PRODUCTS & SERVICES

17

Metal Fatigue in Overhead Cranes

19

Lifting Solutions Suited to the African Market on Show at Bauma

24

The Power of Vacuum

42

Lifting Solutions Specialists

45

HOISTS & TOOLS Lifting by Air

CRAWLER CRANES

Crawler Crane Fleet Provides the Heaviest Lifts

GREENING

Toyota Forklift Helping Woolworths Go Greener

AUTOMOTIVE

Increasing Throughput in the Local Automotive Industry

23 26 29 30

NEWS FROM AFRICA

Three Linden Comansa Tower Cranes At Cambambe Dam - Angola

EXPORTS

Rugged Reliability A Boost to Crane Exports

REGULATIONS

Driven Machinery Regulations, 2015 - Gnr.527 of 2015

32 40 46

Index to Advertisers Akhanani Anchor Industries Bauma Culmen Fastlift Gunnebo Linde MFN Lifting Systems Morris Mphatlalatsane NewCorr Mining Park Lifting Phakamisa RGM Cranes Rhino Lifting Rusch Crane Repair Searle Hoists & Tools Shutterlock/Bridon Shutterlock/Crosby Toco Lifting Verlinde WH Lifting

Disclaimer Opinions in this Publication are those of the DXWKRUV DQG GR QRW QHFHVVDULO\ UHĂ€HFW WKRVH of this publication, its editorial board, its editor or its Publishers LEEASA or CMA. The PHQWLRQ RI VSHFLÂżF SURGXFWV LQ DUWLFOHV DQG advertisements does not imply that they are endorsed or recommended by this Publication or its publishers in preference to others of a similar nature, which are not mentioned or advertised. Reliance on any information contained in this journal is at your own risk.

While every effort is made to ensure the accuracy of editorial board makes no representations or warranties, express or implied, as to the correctness or suitability contained and/or the products advertised in this publication. The Publisher shall not be liable for any damages or loss, howsoever arising, incurred by readers of this publication or any other person/s. The Publisher disclaims all responsibility and liability for any damages, includes pure economic loss and any consequential damages, resulting from the use of services or products advertised in this publication. Readers of this publication indemnify DQG KROG KDUPOHVV WKH SXEOLVKHU LWV RIÂżFHUV employees, and servants for any demand action, application or other proceedings made by any third party and arising out or in connection with the use of any services and/ or products or the reliance on any information contained in this publication.

Lifting Africa - July/August 2015

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4 45 28 5 222 34 27 37 15 18 21 16 17 OBC 36 25 23, 41 38, 39 10, 11 OFC IFC IBC

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"Technology from STAHL CraneSystems is in use whenever sophisticated engineering, high quality and extreme safety standards are required"

Design, Fabrication, Construction of Portable Workshops, Installation and CertiĹľcation of Overhead Cranes, Hoists and Below Hook Lifting, Rigging and Railway Equipment 4

Lifting Africa - July/August 2015

www.akhanani.co.za sales@akhanani.co.za 248 Bosworth st, Alrode South, Alberton P.O. Box 146663, Bracken Gardens, South Africa 1452 Phone: +27 (11) 900-1085

LEEASA is in the process of change, and we are proud to announce that we are on track with our plans mapped out some years ago.

These includes; We have confirmation from the Engineering Council of South Africa (ECSA), that LEEASA is recognised by ECSA as a Voluntary Association.

The long awaited implementation of our “No Profit Organisation” to drive the association forwards is now in full swing.

Ken Greenwood, Chairman

On behalf of all our members and readers, LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SOUTH AFRICA (LEEASA ) takes pleasure in joining our associates in congratulating the publishers of the Lifting Africa magazine and wish them a long and successful journey. This is the dawning of an anticipated communication medium which has a major role to play in our future.

The restructuring of our membership which will include Lifting Tackle Inspectors, Operators and Riggers at all levels and many more.

The introduction of specialised training programs specifically for our industry.

All these new initiatives will be explained and expanded on in the next edition of this publication.

An announcement regarding our next meeting will be on our website in the near future .

Until next time, Ken Greenwood, Chairman. ken@lmi-academy.co.za PS. By now everyone should know that the new Driven Machinery Regulations have been published. LEEASA has issues with this publication and are busy with representation to the Department of Labour already.

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Lifting Africa - July/August 2015

5

ASSOCIATION NEWSÚ

F

rom the Chairman’s Desk

PERSONALITY ROFILEÚ

P

roudly SA Project

Academic Qualification: • Matric • JCI Management and Financial Course • Damelin Marketing Course • Various Safety Seminars First Employer: Smiths Saddlery Mining & Engineering Products (Pty) Ltd-1965-1988 Last Employer: Scaw Metals (foremally Mc Kinnon Chain)-1988-2015 First Salary: R110 Achievements Sales Director, Smiths Saddlery and Marketing Manager at Scaw Metals.

There are a lot of grey areas where legislation is not specific, and often incorrectly interpreted by inspectors, auditors and safety officers who enforce their own opinions and interpretations on the user.

Inferior and sub-standard lifting equipment being imported and used as price, rather that quality, has become the norm fromuninformed buyers.

Lack of properly compiled in house customized lifting equipment written operating procedures that should be adhered to ensure safety in the work place.

Management not enforcing a safe lifting program in the work place.

Lack of knowledge of applicable SANS and other quality standards.

Suppliers, that are not appointed by the OEMs as their agents who sell inferior quality with no technical back up or support.

Development and sales of the only South African manufactured “Compact”- Chain Block.

Educating end users as to their responsibility with regards to OHSA and MHSA lifting equipment Regulations and requirements.

Involved with the introduction of alloy chain slings to SA market in 1967.

Before this, wire rope slings was the only product used for lifting. Chain slings could be assembled on the spot by using mechanical coupling links, such as the hammerlock to attach different types of hooks and customise slings to user’s requirements.

Advice to offer There are numerous products on the market that can be used for lifting.

The type, size and mass of the load will determine whether to use a chain slings, wire rope slings or webbing sling.

Development and design of specialised chain sling systems used in the sinking of mining shafts, not only locally but worldwide.

Supporting a network of lifting equipment suppliers.

Conducting lifting equipment safe and correct use training to users and suppliers of chain sling and hoists nationally.

“There are numerous products on the market that ĐĂŶ ďĞ ƵƐĞĚ ĨŽƌ ůŝŌŝŶŐ͟

A risk assessment and or rigging study needs to be conducted before the lifting operation begins, and a full evaluation of the task to be performed must be conducted

Challenges in Industry as far as lifting equipment is concerned

Assess the typical service conditions, ie, normal, arduous or hazardous before deciding and remember that lifting equipment is safety critical items.

Applicable Mining and Industrial legislation, for lifting equipment, is not clear and often contradicting as far as lifting equipment practice and procedures are concerned.

There is no substitute for safety and only tested, certified and properly marked lifting tackle and hoists should be used for lifting.

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Lifting Africa - July/August 2015

Douglas Poole, Email: dpoole@icon.co.za

The Chain Gang will live for many years to come and there are plans to have a similar function on an annual basis.

The original McKinnon Chain golf floating trophy was handed to the winner on the day.

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Bernard van Rensburg, Peter Parou, Trevor Thomas, Arne Visser Lifting Africa - July/August 2015

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CHAIN GANGĂš

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onorary olf Day

On Friday the 10th of July 2015 the recently founded The Chain Gang proudly hosted a successful golf day in honor of Mr. Dougie Poole at Ruimsig Country Club.

CRANE MANUFACTURERS ASSOCIATIONÚ

D

efragmenting the Industry

If anybody has the right knowledge and depth of understanding as to the nature and characteristics of a particular industry it is the industry participants themselves. So, with legislation and standards being established, the industry needs to participate, otherwise what is set and promulgated by government and its statutory bodies may be inadequate, inhibitive and inappropriately punitive – not just to manufacturers but also to end users. his being said, it was discussed and agreed among the major overhead Crane Manufacturers that the Crane Manufacturers Association be established. The founding members of the association are Akanani, A J M, Condra Cranes, Demag Cranes and Components, F B Cranes, Kone Cranes, Morris cranes, Pro Cranes, RGM Cranes and Verlinde cranes, with Alan O’Hara of Demag the first and duly elected chairperson.

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The purpose and objectives of CMA are: Represent South African overhead crane manufacturers, who are its members and serving them by being a single, united voice in the industry’s interactions with government, be it at a national, provincial or local level, and any statutory bodies, as well any other public or private organisations with regard to matters of concern or interest to the Industry, or to any individual member of CMA. Promote and defend the common interests of its members.

Promote a positive image of the Industry as a whole.

Facilitate the exchange of information that may in any way be relevant to the common interests of its members.

Building relationships with South African, regional and international associations whose interests in any way intersect with or are similar to those of CMA. Promote, in general, all other topics which the Board considers should be dealt with by CMA. 8

Lifting Africa - July/August 2015

O’Hara is very clear. “The CMA wishes to be involved in the Alan O’Hara, Crane Manufacturers process of deterAssociation chairperson mining the most appropriate and applicable SANS standard for Lifting Machinery Inspectors. Our concern is that suitably qualified experienced, persons are not appointed. Safety is not negotiable, no matter how good the past record of the industry may have been,” he said. “The reason for our concern is the instance of non-adherence to operating within the limitations defined by a crane’s classification, whatever the reason may be. In addition, cranes today are built precisely to work cycle specifications e.g. load weight, load frequency and crane life. If a crane is disposed of and the new owner is not aware of that specification, they could operate the crane out of spec, thus causing metal fatigue and failure. In such instances, people invariably get hurt and are even killed,” O’Hara concluded.

While the SANS 10375:2006 Edition 1, titled the Inspection, Testing and Examination of Overhead Cranes, defines a competent person as someone who has the knowledge, training, experience and qualifications specific to the work or task being performed and who is registered by the relevant national authority. As safety is non-negotiable, every measure must be taken to ensure that this standard is upheld.

So, with the classification of cranes of such critical importance, understanding and adhering to these classifications is an imperative. ISO 12482 emphasises what O’Hara said. Cranes are designed for a finite lifetime of duty, which is specified in load cycles and load spectrum and is not principally related to calendar working time. The classification of crane duty provides the crane owner with the means to specify the intended duty of a crane in order to operate that crane in accordance with its intended use and operating lifetime.

The Crane Manufacturers Association (of America) classifies cranes as follows: Class A (standby or infrequent service): This service class covers cranes where precise handlings of equipment at slow speeds with long idle periods between lifts are required. Capacity loads may be handled for initial installation of equipment and for infrequent maintenance.

Typical examples are cranes used in powerhouses, public utilities, turbine rooms, motor rooms, and transformer

stations. This is the lightest crane as far as duty cycle is concerned.

Class B (light): This service class covers cranes where service requirements are light and the speed is slow. Loads may vary from no load to occasional full rated loads with 2 to 5 lifts per hour, averaging 10 feet per lift. Typical examples are cranes in repair shops, light assembly operations, service buildings, light warehousing, etc.

Class C (moderate): This service covers cranes whose service requirements are deemed moderate, handling loads which average 50 percent of the rated capacity with 5 to 10 lifts per hour, averaging 15 feet, with not over 50 percent of the lifts at rated capacity. Typical examples are cranes used in machine shops, paper mill machine rooms, etc.

An industrial overhead crane in action

Class D (heavy): In this type of service, loads approaching 50 percent of the rated capacity will be handled constantly during the work period. High speeds are desirable for this type of service with 10 to 20 lifts per hour averaging 15 feet, with not over 65 percent of the lifts at rated capacity. Typical examples are cranes used in heavy machine shops, foundries, fabricating plants, steel warehouses, container yards, lumber mills, etc., and standard duty bucket and magnet operations where heavy duty production is required.

Class E (severe): This type of service requires a crane capable of handling $Q RYHUKHDG FUDQH IDLOXUH GHPROLVKHG XQRFFXSLHG RI¿FHV DQG QDUURZO\ PLVVHG ZRUNPHQ loads approaching the rated capacity throughout its life with 20 or more lifts per hour at or near the rated capacity. Typi- for the regular maintenance of cranes. While both are cal examples are magnet, bucket, magnet/bucket com- critical, monitoring and inspections serve different purbination cranes for scrap yards, cement mills, lumber poses. Both must be carried out and serve the purpose for which they are intended. One cannot and does not mills, fertilizer plants, container handling, etc. replace the other.

Class F (Continuously severe): In this type of service, the crane must be capable of handling loads approaching The design working period (DWP) is derived from the rated capacity continuously under severe service condi- design classification of a crane and is not to be considtions throughout its life. Typical examples are custom ered as a guaranteed operational period in any respect. designed specialty cranes essential to performing the Due to the probabilistic nature of metal fatigue and critical work tasks affecting the total production facility, other influencing factors, premature failures during the providing the highest reliability with special attention DWP cannot be ruled out. However, the DWP represents a reliable estimate of a safe operational period of the to ease of maintenance features. crane, with due consideration to specified design reguThe monitoring of a crane’s use does not in any way lations and standardized design safety factors – somechange the requirements for periodic inspections, re- thing we will look at in the next issue of Lifting Africa. gardless of the nature and type of instruments used for monitoring. Neither does it remove the requirement By Tony Stone Lifting Africa - July/August 2015

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Lifting Africa - July/August 2015

DIRECTION OF LIFT 100% WLL 70% WLL

1 3

70% WLL

50% WLL

50% WLL

2 4

100% WLL 70% WLL

70% WLL

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Lifting Africa - July/August 2015

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COVER STORYÚ

T

oco - Lifting New Heights

Toco Lifting, a leader in the South African lifting, lashing and rigging industry, is enhancing their footprint through Africa. We wanted to know more about the company, and what they can offer to the market.

They specialise in the importation, supply, assembly and repair of an extensive range of materials handling equipment. Toco’s market primarily covers the industrial, mining, shipping, construction, and manufacturing sectors, but they also serve the agricultural, marine and fishing industries.

When asked what their primary objective is, Executive Director, Jonty Walls, would tell you that it

is to provide exceptional service.

Whether sales, repairs or testing, they have both the expertise and premium products to achieve this consistently. Toco has been earning customer confidence for the past 14 years through their passion, knowledge and commitment to all their clients.

“We have distinguished ourselves from the rest by adding value in terms of the quality of the services we offer” They see themselves as having a responsibility to be more than just a supplier, but to be a partner in their customers’ success, boosting performance and productivity

2200m of 42mm winding rope for a mining application

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Lifting Africa - July/August 2015

with their quality equipment and helping them get the job at hand done. Toco has played an integral role in various aspects, including products, consultation, advice and cost effective alternate options, on projects from the smaller right through to the larger mechanical turnkey projects like work done at Kusile Power Station.

“We have distinguished ourselves from the rest by adding value in terms of the quality of the services we offer. Service is our primary objective which includes extremely short turnaround times on the assembly of all types of wire rope slings, chain slings and synthetic slings” Walls said, “In this well-established industry people generally know the available products, but they might not know the most effective approach, which could lead to serious consequences, and this is where Toco can help. We are registered

Lifting for Alstom: 2 x 100 Ton double leg hawser-spliced grommet sling assemblies lifting 170 tons with ease

clamps and turnbuckles, as well as wire rope, chain and nylon slings, which is made up in-house according to the customer’s needs” While chain blocks and lever hoists are one of their primary products ranges, steel wire rope is another speciality. “This ranges from simple stuff like PVC coated wire used for pull wires on conveyor systems, right through to steel rope used on overhead, tower and mobile cranes.

We also have all types of steel rope for winches as well as our in-house facility to assemble steel wire rope slings from a diameter of 1mm

Our New Home In Germiston

with the Department of Labour as an LME (Lifting Machinery Entity) and are members of the Chamber of Engineering Technology (COET) and Lifting Equipment Engineering Association of SA (LEEASA).”

Toco, also boast the employment of experienced and knowledgeable staff, this includes an LMI (Lifting Machinery Inspector). This means that they are able to tailor the most effective solution for each client’s needs, and underlies the company’s success. As Walls shared, “A fair measure of the quality of a company is the amount of repeat business it receives. We listen to our customer’s needs and exceed their expectations, and as a result they are satisfied with the equipment they purchase from us, not only today, but in the future.”

It is with this in mind that Toco Lifting recently launched a new website; www.toco.co.za. Visitors and customers can now browse through the products offered, see product information, and request quotations or information hassle-free online. Convenience and efficiency is key. This support their commitment to building a community of Toco customers throughout Africa.

Footprint Toco’s Head Office and principle distribution centre is situated in Gauteng, South Africa. Mr. Walls explained that “We have recently purchased a premises in Germiston, which has allowed us the space to expand further. We are able to

Toco’s warehouse buzzing with activity

keep a much larger inventory of stock on hand, which once again enhances our turnaround times and supports our goal of service excellence”. Toco’s coverage has already stretched well into Africa.

“We’ve been to other countries, such as Zambia and Zimbabwe to address wire rope problems on drill rigs and have been on innumerable mines. Often the end user is not fully aware of all the factors which influence the choice of wire rope, and so we go out to investigate, to work out a solution for that specific application.”

Products The company specialises in Lifting Equipment below the crane hook; consumables that regularly need replacing to comply with safety requirements. Jonty added, “Our range covers world-class Vital chain blocks and Vital lever hoists, steel wire ropes, chain and rigging hardware such as shackles, wire rope

right up to 56mm”. All associated specialised services are also on offer, for example socketing, hand splicing and load testing.” Jonty shared.

Toco’s flagship product range is the internationally acclaimed Vital ® Chain Blocks and Lever Hoists.

Vital ® is the most extensively used chain block worldwide, and for solid reasons! This heavy duty chain block is designed for extended use at the lowest possible cost per use.

Pricing, size, weight, mechanical advantage and efficiency sweeps the competition away! The equipment is designed for reliability, easy operation and uncompromising safety.

This allows for many advantages.

As gears take the most strain under a full load, Vital ® units have been designed so that strain and backlash is greatly reduced, allowing for minimal wear and tear on Lifting Africa - July/August 2015

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COVER STORYĂš

hooks, and a standardised high grade chain, sourced from McKinnon Chain, a Division of Scaw Metals; an SABS and ISO compliant chain manufacturer. One can find no other to rival in price vs performance, and that is why Toco Lifting is proud to be the sole agents of the Vital ÂŽ Chain Blocks and Vital ÂŽ Lever Hoists in Southern Africa.

Maintenance and Repairs Lifting equipment, by its very nature, is under constant stress and therefore it requires regular maintenance to sustain capacity, safety and reliability. This maintenance should only be carried out by experienced staff who have the necessary knowledge and skills, and Toco, is filling this role, aspires to be the service champion in their industry.

They are dedicated to the highest level of customer service over the life of their equipment. They strip, quote and repair all types of lifting and rigging equipment, including manual hoists, electric hoists, pneumatic hoists, winches and chain slings. They then test the equipment on testing benches, and once they are satisfied with the quality of repair, a certificate for each repair is supplied.

A wide range of spares are carried by the company, and original parts are sourced where required. Their reputation has been established as a company that offers expertise, experience and in-house equipment to conduct professional inspection, testing and repairs in accordance with all applicable regulations, standards and engineering practices, ensuring that even products sold by other suppliers are brought to Toco for repairs and maintenance. Tested and repaired products leave the company recertified and ready for use.

Toco Lifting’s dedication to service and integrity is a clear winner

Vital chain block and lever hoist

“What we value the most is the relationships we build up with customers in the long term,� Jonty says in conclusion. “It’s very important to provide your customers with the best value for money while maintaining the integrity of the product once we’ve sold it to them by providing jacked-up after-sales service�.

the gears. Vital has a unique spine fitment design of the hand wheel to the pinion shaft that offers easy maintenance and enhances the mechanical friction braking system, the overall effect being one of great efficiency and longevity of the unit.

Vital ÂŽ units are fitted with a double ratchet pawl that is SANS1636 compliant, a mechanical friction braking system that is further strengthened with high quality, high performance abrasive brake disks.

To complete the high performance of these hardy chain blocks and lever hoists, they are fitted with anti-slip 14

Lifting Africa - July/August 2015

Specialists in Lifting, Rigging and Lashing Equipment Contact : 086-111-TOCO (8626) +HDG 2IÂżFH 7HO &DSH 7RZQ 7HO www.toco.co.za

Fatalities caused by falls from elevation continue to be a leading cause of death for construction workers, accounting for 269 of the 775 construction fatalities recorded in 2012. According to Scott Owyen, global training manager for Terex AWP, those deaths could have been prevented. In honor of OSHA’s National Fall Prevention Stand-Down, June 2 – 6, Terex AWP is providing the following safety tips for operating powered access equipment to reduce the likelihood of a potential deadly fall. ake sure that you have received proper training (both general training and hands-on practical training) as well as familiarization on the MEWP you will be using. Thoroughly read the operator’s manual and safety signs on the machine, and understand the function and location of all safety devices and controls before beginning operation.

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Always read, understand and obey employer’s safety rules and worksite regulations, as well as all applicable local, governmental or provincial regulations that apply to MEWP operation before operating the machine.

Always wear the proper fall protection when operating either a telescopic or articulating boom. A properly fitted full body harness and appropriate lanyard or self-retracting lifeline is an absolute requirement. Most operators do not understand the potential for being catapulted from the platform of a boom. The slightest jar at the base of the machine can equate into a sudden and powerful whiplash at the platform that may have the potential to toss the operator into the air. If this were to happen, wearing the proper fall protection may reduce the chances of serious injury or even death.

Always perform a pre-operation inspection and function tests on the MEWP before each shift. A level sensor, alarm or any other safety device cannot do its job if it has been disabled or has malfunctioned. If the machine fails any of these tests, make sure it is immediately tagged and removed from service until it can be repaired by a qualified service technician.

Always perform a workplace risk assessment prior to moving the MEWP to the job site. Look for drop-offs and holes, slopes, slippery or unstable surfaces, overhead obstacles, power lines and any other hazards that may exist. Then consciously think about and avoid those hazards through all phases of machine operation.

A full list of hazards you need to be aware of can be found in the operator’s manual for the machine you are operating.

Never sit, stand or climb on the platform guardrails for any reason. The guardrails on a MEWP provide fall protection only if the operator maintains a firm footing on the platform floor at all times. If an operator is required to reach an overhead work area that is too small for

Lifting Africa - July/August 2015

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HEALTH & SAFETYÚ

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op 10 Safety Tips for Powered Access Operation

HEALTH & SAFETYÚ

approval letter from the manufacturer that provides the proper guidance.

Never climb down from the platform when it is raised. Whenever possible, keep a cell phone or two-way radio with you while you are in the platform. Always have a rescue plan in place in the event that the MEWP is not equipped with an auxiliary lowering system or if that system malfunctions. Rescue plans should at a minimum include steps to ensure that other personnel are aware that you are operating the MEWP and that they have been trained and familiarized to operate the machine from the ground controls.

the platform guardrails to allow access to, the use of a manufacturer-approved device that has been specifically designed to provide additional access to confined spaces is recommended.

Never exit an elevated boom or scissor lift platform unless you have been properly trained to do so, maintain 100% tie-off at all times, and are in possession of an

Always keep the platform floor clear of debris. Scrap materials, buckets, large tool boxes and other items can cause a serious tripping hazard. You should remove any item from the platform that is not absolutely necessary to do your work. Utilize special manufacturer-approved attachments such as fluorescent tube caddies or panel cradles (where applicable) to lift large or bulky items.

Always lower the platform entry mid-rail or close the entry gate before operating the MEWP. The entry midrail or gate is an integral part of the platform guardrail. Never tape or prop the entry open and never use a MEWP if the gate does not properly latch.

YOUR LIFTING SPECIALISTS PARK LIFTING SPECIALIZES IN THE SERVICING, REPAIRS, LOAD TESTING AND SUPPLIES OF: ¾ OVERHEAD CRANES AND TRUCK MOUNTED CRANES. ¾ FORK LIFTS; CAR LIFTS; ELECTRIC AND PNEUMATIC HOISTS. ¾ CHAIN BLOCKS; LEVER HOISTS AND ALL LIFTING EQUIPMENT.

CONTACT US: TEL: 017 687 0236 FAX: 017 687 0239 CELL: 079 743 7297 CELL: 082 900 2563 EͲMAIL: johan@parklift.co.za EͲMAIL: frans@parklift.co.za 16

Lifting Africa - July/August 2015

INSPECTION & TRAININGÚ

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hain Blocks & Lever Hoists Operation, afe Use & Inspection Course

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The correct use, maintenance, inspection and testing of chain blocks and lever hoists, referred to as hand powered lifting devices in the new OHSA DMR 18, is essential to be legally compliant and to maintain safety in plants, mines and industry.

It is a fact that hundreds of thousands of these units are in use and are often abused, overloaded, incorrectly inspected and poorly maintained.

With this in mind and to assist users, Phakamisa Safety Consultants have added this new course to their other specialized lifting equipment management and inspection courses, which are conducted on site or at pre-arranged venues in major centres This unique half day intensive course has been designed by Phakamisa, in cooperation with major hoist suppliers, to assist supplier’s technical representatives, users, inspectors, artisans, safety staff, Riggers, LTIs and LMIs to gain the necessary knowledge of the operation, safe use, inspection and maintenance of hand powered lifting devices as well as other equipment such as suspension trolleys.

The course covers all legal requirements in accordance with OHSA-DMR 18 and MHSA requirements as well as definitions, marking, certification, SANS and other quality standards as well as LME and LMI requirements.

The course will assist users to conduct visual daily and mandatory visual inspections on hoists and maintain and store properly.

Hoist Inspection check lists are provided for a proper visual inspection.

Hoists must be visually inspected, in accordance with proper inspection check lists, by persons who have been appointed, by company management in writing, based on that person’s experience, knowledge and training to conduct mandatory visual inspections.

Hoists must also be load tested at maximum intervals of twelve months, by companies registered as LMEs with the DOL. These LMEs must employ or contract suitably qualified ECSA registered LMIs who have the scope to conduct tests on hoists.

This intensive training course provides the necessary knowledge required for selected and experienced candidates, through properly structured course modules and demonstration to be Lifting Africa - July/August 2015

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HEALTH & SAFETYĂš

program, by all candidates. Certificates will only be awarded to those who achieve a pass rate of 70%.

As far as accreditation is concerned, this specialized course is unique and no specific formal SAQA Unit Standards exists for it.

The course is essential for the hoist component of LMI and LTI training The course is validated by ECSA for CPD points.

It is essential to note that candidates who are nominated for this intensive course must be carefully selected by management by virtue of their background, experience and practical skills and ability to conduct proper inspections after completing the course.

Remember, safety is not negotiable and all lifting equipment, including chain blocks and lever hoists must be regarded as safety critical items!

Piet Otto, who is a lifting equipment specialist, with over 45 years of lifting equipment experience for any further advice at Phakamisa Safety Consultants. legally compliant and safe in the work place.

course is issued on successful completion of the course.

A Certificate of Attendance listing all the modules covered in the

A comprehensive written assessment is conducted at the end of the

Piet Otto, Cell: 082 372 4595, Email:potto@icon.co.za, www.phakamisasafety.co.za

MPHATLALATSANE LEARNING RESOURCES CC. (Prosperity you have always being dreaming of) Reg: 2008/242073/23 VAT: 4370252035 SETA Reg. No. TETA09-194 CPHA Membership no: MPH001 Department of Lab our NSF no: 4497 In association with the registered LME

We offer the following training courses on your site so as to prevent interruption to production!!! x

Overhead crane operator training

x

Forklift operator training

x

Basic rigging& related courses

x

Mobile crane operator training

x

Truck mounted crane operator training

x

RIGGING QUALICATION NQF Level 2 & 3

We strive to change your operators behaviour Mobile: 083 522 9627 071 952 0919 Office: 016 931 9437 E-mail: percy@mphatlalatsane.co.za

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Lifting Africa - July/August 2015

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PRODUCTS & SERVICESÚ

etal atigue

in Overhead Cranes The downside of a preventable accident is the avoidable injury or death, caused as a result. Not to forget the costs involved. Causality teaches us that accidents caused by metal fatigue are solely attributable to negligence. alking into a Meyerton factory that produces spirally welded steel pipes, I asked the safety officer why he had not given me a helmet, but had insisted I wear ear plugs and a reflective vest. He pointed to the coil of sheet steel hanging from the overhead crane and explained, “That coil weights 30 tonnes. If it falls on you, a helmet won’t matter at all.” A valid point indeed! Without another thought, we continued into the factory. On reflection, I should have considered the issue a little more.

Over the years the overhead crane could have suffered metal fatigue, and failed. Was this a real possibility, or just a little imagination off on the wild side?

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“Causality teaches us that accidents caused by metal fatigue are solely attributable to negligence”

When initially classified, this overhead crane was regularly lifting 22 tonne coils. With advances in steel manufacture, coil weights increased to 30 tonne, giving a 36% increase in weight above the original classification. If the overhead crane was not upgraded, this would have exposed it to loads above and beyond its design capacity, and effectively shortened its life, which is usually 10 years.

Could this possibly happen? In South Africa, with its normal rate of staff attrition, BEE legislation and exodus of skills, corporate memory and intellectual capital often do walk out of the door. Eskom is but one example.

While failures due to metal fatigue don’t occur very often, they do occur. In one accident, the shaft in an overhead crane motor failed. Professor Sara Rodriguez, assisted by Oscar Zambrano and JJ Coronado from of the University of del Valle’s mechanical engineering department, and members of a research group looking into metal fatigue failures, analysed the failure of the shaft.

“The shaft fractured in the keyway with clear evidence of fatigue. Chemical analysis, micro-structural characterization, fractography, hardness measurements and finite element simulation were used for the analysis.

The microstructure was predominantly tempered martensite. Large amounts of oxides, micro pores and manganese sulphide inclusions were found. The geometry of the keyway also initiated the original crack because the width and height were erroneously designed,” Rodriguez said.

“From this we concluded that these factors in combination produced the fatigue failure,” Zambrano added.

“From our analysis and conclusions, we recommend that the chemical composition and microstructure of Lifting Africa - July/August 2015

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PRODUCTS & SERVICESÚ

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Out-of-plane shear: a shear stress acting parallel to the plane of the crack and parallel to the crack front

The Goodman Relation is an equation used in linear elastic fracture mechanics to quantify the interaction of mean and alternating stresses on the fatigue life of a material. The Goodman diagram is a graph of (linear) mean stress versus (linear) alternating stress, showing when the material fails at some given number of cycles.

A cut out of the overhead crane and the shaft that was analysed

the material, at time of manufacture, must conform to regulatory standards, and be guaranteed. That magnesium or calcium additions in the steel casting process, to obtain better shape control of inclusions, should be used. And lastly, that the geometric parameters recommended by the regulatory standard, to avoid high stress concentration factors, should be met,” Rodriguez concluded.

As Kai Qi, Guangzhou’s academy of special equipment inspection and testing explained, “Based on fatigue crack growth analysis, linear elastic fracture mechanics (LEFM), the study of the propagation of cracks in materials, can be used to describe, and predict, fatigue crack growth in the life estimation process of metal components of a crane.”

There are three ways force can be applied to enable crack propagation: ¾

Opening mode: a tensile stress normal to the plane of the crack

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In-plane shear: a shear stress acting parallel to the plane of the crack and perpendicular to the crack front

The three fracture modes 20

Lifting Africa - July/August 2015

“Safety has no price.

Accidents can be avoided.

Metal fatigue can be avoided”

The Goodman relation can be represented mathematically as:

Where is the alternating stress, is the mean is the fatigue limit for completely reversed stress, is the ultimate tensile stress of the maloading, and terial. The general trend given by the Goodman relation is one of decreasing fatigue life with increasing mean stress for a given level of applied stress. The relation can be plotted to determine the safe cyclic loading of a part; if the coordinate given by the mean stress and the applied stress lies under the curve given by the relation, then the part will survive. If the coordinate is above the curve, then the part will fail for the given stress parameters.

In another instance, as Mark Firth, senior consulting engineer at Hanson Materials Engineering, relates, “The driveshaft of a 36 tonne capacity overhead crane in use in a foundry had failed after slightly less than one year's service. The shaft was 188 mm in diameter at the point of failure. It was a replacement unit which had been machined from plain carbon shafting steel (0.4% C).”

“From visual examination of the fracture face, it was obvious that the shaft failed beccause of fatigue. The fracture had in initiated at four locations and had tw two distinct origins - at a minor cchange of section of the shaft from 1 188 to 191 mm, and at the base of tthe end of a keyway.” ““The fatigue fracture occupied app proximately 40% of the shaft cross ssection. The remainder of the cross ssection showed a ductile torsiona al failure. The change of section o of the shaft diameter was fully rad dius’d (1.6 mm), but appeared to h have been made with a worn tool

because the fillet had a rough surface containing many grooves. The base of the keyway was also sharp and had no radius.”

These deficiencies in machining were considered to be the major cause of fatigue failure.

“The material itself was open to criticism; although the shaft had a normal ferrite-pearlite microstructure characteristic of a shafting steel, the hardness at HB 176 was lower than the typical value (HB 192) quoted by the steel manufacturer. Tensile testing of samples of shaft material showed that although tensile strength levels were in accordance with the manufacturer's typical value (655 MPa), yield strength levels (328 MPa) were appreciably lower than the typical value (393 MPa). Low yield strength no doubt contributed to the fatigue failure,” Firth concluded.

But, it’s not just driveshafts that fail. Other components of overhead cranes can also fail, such as: ¾

Bolt slackness / poorly welded joints

¾

“I” beam support failure

¾

“I” beam failure

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Hoist rope failure

The Goodman Relation diagram

What is clear from these and other examples of metal fatigue failure is that negligence in manufacture, shortcuts in maintenance, pushing an overhead crane beyond its design life, or designed load classification, and ultimately a failure of the regulatory inspection cycle to identify and/or prevent fatigue is what causes accidents.

When it comes to safety, the attitude “we had to cut costs” is a negligent one, as is “it will never happen to me”. Safety has no price. Accidents can be avoided.

Metal fatigue can be avoided.

By Tony Stone

Lifting Africa - July/August 2015

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Lifting Africa - July/August 2015

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Searle Hoist & Tool (Pty), a Level 4 Black Economic Empowerment company, was founded in 2005 as an importer and distributor of heavy duty, SANS & other industrial codes compliant, lifting equipment. The products are tested tand accepted by mining, petro-chemical, construction, marine and general industries of Southern Africa.

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he Company is a subsidiary of Edward Searle (Pty)ltd which was originally founded in 1896, and has branches in Johannesburg, Pretoria, Durban, East London & Cape Town with distributors throughout South & Southern Africa.

In accordance with the objectives of the Broad Based Black Economic Empowerment Act, certain of the long servicing, senior male and female Previously Disad-

HOISTS & TOOLSĂš

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vantaged Individuals in the Searle & Sapco Divisions of Edward Searle (Pty) Ltd who have and continue to contribute to the efficiency of the business, have been recognised& appointed as shareholders and fill certain management & Director portfolios in Searle Hoist & Tool (Pty) Ltd. Searle Hoist & Tool (Pty), management, sales & technical staff are highly experienced and competent in the field of lifting equipment and are longstanding members of National Regulatory bodies & Associations responsible for SA National Standards & Industry Codes.

Our KiNG registered brand of manual chain blocks & lever hoists, mining & industrial style pneumatic chain hoists, electric chain hoists & trolley units have been specifically designed to be safe and fit for purpose in conformance with the relevant SA National Standards, Mine Health and Safety act, Occupational Health & Safety Act and recognised international standards.

Quality is assured by our ISO 9001 certified International specialist manufacturers ensuring consistent and high quality products.

Rob Darby, Edward Searle, Tel. (021) 511-2250, Email: robdarby@iafrica.com, www.edwardsearle.co.za

Searle strip 1

Lifting Africa - July/August 2015

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PRODUCTS & SERVICESÚ

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ifting Solutions Suited to the African Market on Show at Bauma Torre Lifting Solutions will use its presence on the Torre Industries stand at Bauma to showcase its comprehensive lifting solutions to the local and African market. Incorporating SA French and Elephant Lifting Equipment, Torre Lifting Solutions offers a large and diverse footprint of customised lifting and materials handling solutions from respected leading brands.

he company’s quality-centric business philosophy is underpinned by its solid base of applications knowledge and experience which is enhanced by the extensive distribution network of Torre Industries. The end result is a total lifting solution from consumables to tower cranes and overhead cranes.

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Lifting Africa - July/August 2015

The company offers a genuine single supply source for tower cranes, purpose built overhead cranes, slings, shackles, concrete buckets pallet forks and brick baskets. It is the sole southern African distributor for the reputable Potain range of tower cranes. According to technical director of Torre Lifting Solutions Quentin van Breda, it has been recognised as an Elite Dealer

by Potain of France, which means a guarantee of 80% availability of spare parts on first call.

“Access to parts and consumables is critical as many of the projects on which our equipment works are of a fast-track nature. In addition to the Potain tower cranes, we also distribute a hoist range from Orbit as well as offer this product on rental. Dieci telescopic handlers and self-loading mixers are a new addition to the product line up, and we operate a rental fleet of tower cranes, telescopic handlers , hoists, slings, concrete buckets, pallet forks and brick cages, with a very high utilisation rate,” van Breda says. The smallest machine in the tower crane rental fleet is a Potain IGO 22 self erecting crane with a 28 metre radius, while the largest is a Potain MD310 with a 70 metre jib and a capacity of 3 tons at 70 metres.

Notably, Torre Lifting Solutions operates a manufacturing facility in Pretoria West where lifting and material handling solutions are customised for specific application requirements.

Products include EOT cranes, monorails, electric chain hoists, chain and lever blocks, winches and wire rope pulling machines, lifting and spreader beams, mechanical grabs and clamps, slings (chain, polyester and steel wire rope), shackles and rigging accessories. This market offering was recently extended with the addition of 30 ton capacity overhead crane and an ultra-compact steel wire rope hoist, which is suitable for lifting in areas where height restrictions or confined spaces are an issue.

An LME (Lifting Machinery Entity) accredited company, Torre Lifting Solutions is a complete single source solutions provider supplying customers with the design, fabrication, engineering, installation, commissioning, support and service, load testing, inspections, repair and refurbishment of all lifting equipment. All equipment is mechanically simple without compromising on the features that are required to provide reliable and safe lifting capability.

The ultra-compact Tusker Low Headroom Hoist is reputed to be the lowest headroom hoist available on the market

“Torre Lifting Solutions is able to leverage years of experience in the harsh operating conditions of the African market to devise customised solutions for every lifting requirement across a number of industries.

Access to a highly knowledgeable technical team provides fit-for-purpose solutions that achieve increased productivity and safety, with decreased downtime and maintenance,” van Breda concludes.

Quentin Van Breda, Torre Lifting Solutions, Tel: (011) 822-8782 Email: quentin@safrench.co.za, www.safrench.co.za

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CRAWLER CRANESÚ

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rawler Crane Fleet Provides he Heaviest Lifts

Undertaking a heavy lift is not a case of ‘one size fits all’ but rather about selecting the most appropriate lifting solution for a given project or contract.

This is according to Johnson Crane Hire, which boasts a heavy lifting capacity unmatched on the continent.

Ultimately, a successful heavy lift is determined by the technical expertise of the heavy lift supplier. Johnson Crane Hire has a breadth of resident knowledge that enables it to provide best practice heavy lift solutions in a turnkey project approach that includes rigging and transportation,” says James Robinson, heavy lift manager for the crawler cranes and projects division at Johnson Crane Hire. “We are able to offer flexibility in terms of heavy lifting solutions because we operate a crawler crane fleet and a hydraulic mobile crane fleet as well as alternative lifting solutions.”

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Robinson points out that the three largest cranes in the Johnson Crane Hire fleet are its 750 ton and 600 ton lattice crawlers and its most recent addition – a 750 ton truck mounted lattice mobile unit. “This level of heavy lifting capacity provides continuity and shows our level of commitment to the market by providing them with access to an unequalled combination of heavy lifting capacity and technical expertise.”

Robinson cautions that there is a critical need to recognise that a lattice boom crawler crane offers a vastly greater lifting capacity when compared to mobile hydraulic crane lifting capacities. It is not uncommon to find people making the mistake of comparing one with the other as the nomenclature can be very misleading.

Commissioning of a 750 t crawler crane at Liebherr 26

Lifting Africa - July/August 2015

As an example, Robinson points out that the 250 ton lattice boom crawler competes against a heavy lift 400 ton hydraulic mobile crane. These machines have equivalent lifting capacity, but this not obvious to those that do not understand the differences between lattice boom machines and mobile cranes. The nomenclature should not be used as the manner in which to differentiate between capacities and capabilities.

“In explanation, a hydraulically operated mobile crane’s lift capacity is rated on what is referred to as the load moment. Most hydraulic cranes are rated at their capacity at 3 metres, whereas the rating for a lattice boom crane is based on a larger load moment, which can be anywhere between 7 to 14 metres and this capacity is based on its structural integrity. In essence, a lattice boom crawler crane is capable of performing far heavier lifts and offers greater flexibility in terms of its application because of its pick and carry capability,” he says.

There are distinct limits with regard to the amount of counterweight that can be placed on a hydraulic mobile crane and this is where a crawler crane excels. The lattice boom configuration allows for the attachment of an additional counterweight most often referred to as the super-lift ballast. Crawler cranes are able to increase their load moment by balancing the load to be lifted against the super lift ballast.

Johnson Crane Hire has a ten year history in the crawler crane market and has amassed a number of impressive lifts, including a recent heavy lift at Zimplats. “We were contracted to remove an old mill weighing 225 tons, with a radius of 31 metres, and to replace it with a new one weighing 170 tons. We then brought in an LR 1600-2 (600 ton) crawler crane from Europe to perform this work. The crane is now part of our permanent fleet,” Robinson says.

Johnson Crane Hire also used the LR 1750 (750 ton) crawler crane to lift a 280 ton tippler in Mozambique for the Nacala port upgrade project. A notable feat achieved by the team was the lifting of the 280 ton assembly in one execution. The company is also actively involved in heavy lifts for the major expansion underway at a diamond mine in South Africa. A recent lift at this mine required the lifting of a 110 ton structure with luffer and full super lift configuration at a 55 metre radius. There are additional lifts planned for equipment of 200 tons at 35 metres in the same configuration.

One of the 750 t crawler cranes at the installation of a new 400 t furnace Peter Yaman, Johnson Crane Hire, Tel: (011) 455-9242 www.jch.co.za

MEET THE FAMILY

On all lifts, the company provides a full pre-lift feasibility study that includes computer simulated drawings, generating method statements, full risk assessments and load studies. Operation of the well maintained crawler fleet is supported by an experienced technical team with in-depth knowledge.

Safety in the complex operation of heavy lifts is paramount. “Adherence to safe operation comprises a number of critical elements. Firstly, our machines are current technology and well maintained, and our operators are skilled and comprehensively trained. In addition, we implement carefully documented and implemented safety systems, which comply with all industry safety standards. This is complemented by the risk assessments conducted before each lift. We are justifiably proud of the fact that safety as a culture is ingrained in every Johnson Crane Hire employee,” says Robinson. Safety in fact forms part of the company’s holistic lifting package, referred to as the ‘SMART’ (Safety, Maintenance, Availability, Reliability and Total cost effectiveness) philosophy.

Our combination of multi-faceted handling equipment means that Linde machines are perfectly equipped for big jobs, small jobs and everything in between. With our comprehensive logistical know how, Linde has fast become the industry symbol for superior quality, seamless functionality and innovation. Available to lease, rent or on hire purchase, investing in Linde PDFKLQHV HQVXUHV WKH UHPDUNDEOH HIľ FLHQF\ RI HDFK member of our family.

Linde Material Handling

For more information on Linde dealerships, products and services contact us on Tel : +27 11 723 7000 or visit www.linde-mh.co.za

Lifting Africa - July/August 2015

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E FO ANC RATIONS R T N E IST FREEINE REG n/ L ON om/e c . a c ri ration t .bcaf wwwors/regis t i vis

AFRICA’S PREMIER CONSTRUCTION AND MINING TRADE FAIR

BAUMA CONEXPO AFRICA is the continent’s biggest trade fair for the mining and construction industry.

As home of the HEAVYWEIGHTS, BAUMA CONEXPO AFRICA 2015 promises even more of the industry’s top exhibitors, both international and local.

Over four days the brands exhibiting at BAUMA CONEXPO AFRICA will gain massive exposure to an audience that really matters. It’s an opportunity to meet other world-class brands in the industry, connect with customers from across the continent and expand your business potential.

International Trade Fair for Construction Machinery, Building Material Machines, Mining Machines and Construction Vehicles.

WWW.BCAFRICA.COM MMI/BCA/Quirk/CEN

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Lifting Africa - July/August 2015

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2015/07/02 9:43 AM

GREENINGÚ

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oyota Forklift Helping Woolworths Go Greener ment because of their international award winning Toyota I-site fleet management solution which would further increase safety levels in their warehouses.

Toyota I_Site

n addition to the existing Toyota forklifts in Woolworths’ fleet, three wheel electric forklifts were supplied as well as IPX4 rated four wheel electric forklifts, which are the world’s first electric forklifts with the ability to operate in the rain. BT Reach trucks, order pickers and LPE power pallet trucks also complemented the supply of the electric counterbalanced trucks.

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About 3 years ago, Woolworths was operating 50 units with 5 different vendors over 3 sites. “Our fleet had been purchased on an ad hoc basis and specifications had never been standardized. A renewal program was initiated with the following primary aims in mind; 1 national MHE vendor, standardized national specifications and clear end to end costing. Toyota Forklift offered these as well as a relationship that allowed for mutual growth,” described Michael-John Newham from Woolworths.

“We delivered material handling equipment according to the customer’s specifications which was fitted with world leading and first in the country Trak air system batteries and chargers with Battery WIQ, a wireless monitoring tool for the batteries,” explained Leric Smith, Product Manager for Toyota Forklift.

Innovation Woolworths is known for its passion in quality and innovation as well as bringing in new concepts to ensure safety in the warehouse. The retail group introduced Tyri BluePoint LED lights for use in their warehouses. The coloured concentrated light beam displays a large and visible square on the floor in front or behind the machine to alert workers that a machine is approaching.

This industry leading concept allows safety to be visual instead of relying solely on sirens and alarms, especially in loud noisy workplaces where hearing is difficult.

Woolworths went on to select Toyota Forklift’s equip-

Toyota I_Site is an advanced fleet management business solution that helps companies optimise their fleet size by increasing safety, reducing cost and improving productivity.

“Continuous customer support for Toyota I_Site is available from trained and certified specialists,” notes Smith.

“The various features of this system all help to improve efficiencies and give information to ensure proper and informed central management of the entire fleet,” he adds.

According to Newham, the new machines have improved cross docking efficiencies ensuring product is loaded quickly, safely and on time. The retail giant is now able to move 3 picking bins at a time instead of only one bin with the previous machines.

“Pallet put-aways and retrievals are a lot faster as well as smoother lift speeds, thanks to the modern equipment,” he adds.

“Longer operating times on all equipment also improved with all equipment being AC power and the addition of TRAK Air chargers. The inclusion of the I-site system and access to Toyota Forklift’s well-trained and managed support services has allowed the partnership to grow and enrich both parties,” noted Newham. “The tools available on this system ensure correct spread of equipment is being used to ensure maximum uptime.”

“The pre-check op devices installed on Woolworth’s machines play a big role in assisting a business go green as it saves paper and ensures drivers do their daily checks; a legal requirement, and to make sure the equipment they are about to operate is safe to use. Equipment is thus properly looked after, increasing the life span of the equipment,” advises Smith. “This system helps achieve an initial upfront investment saving and lowers cost of abuse and inefficiency costs over the term,” he concludes.

Leric Smith, Toyota Forklift, Tel: (011) 395-0600 Email: lerics@eiegroup.co.za, www.eiegroup.co.za Lifting Africa - July/August 2015

3 AM

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AUTOMOTIVEÚ

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ncreasing Throughput in the Local Automotive Industry ŚĂŶĚůŝŶŐ ƌĞƋƵŝƌĞŵĞŶƚƐ͘ dŚĞ ŵĂŝŶ ĨĞĂƚƵƌĞƐ ŽĨ D^ ĂƌĞ ĂƐ ĨŽůůŽǁƐ͗ Ease of installation due to light aluminium construction Silent and smooth operation from polyurethane wheels running on aluminium (no metal flaking) High transfer speeds Accuracy of positioning Low maintenance and running costs >ŽĐĂůůLJ ŵĂŶƵĨĂĐƚƵƌĞĚ ƚŽ ƵƌŽƉĞĂŶ standards

Mono rail system

The Port Elizabeth branch of specialist crane and component manufacturer Demag has been supplying its unique Demag Mono-Rail System (DMS) to the South African automotive industry for the past decade. ______________________

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>Žǁ ŵĂŝŶƚĞŶĂŶĐĞ ƌĞƋƵŝƌĞŵĞŶƚƐ ĂƌĞ due to the fact that there is no metĂůͲƚŽͲŵĞƚĂů ĐŽŶƚĂĐƚ ŽŶ ĂŶLJ ŵŽǀŝŶŐ ƉĂƌƚƐ͘ dŚŝƐ͕ ŝŶ ƚƵƌŶ͕ ĞŶŚĂŶĐĞƐ ƚŚĞ ƌŽďƵƐƚŶĞƐƐ ŽĨ ƚŚĞ ĞŶƟƌĞ ƐLJƐƚĞŵ͘ ͞KƵƌ aluminium system uses polyurethane ƚLJƌĞƐ ƚŽ ƉƌĞǀĞŶƚ ŵĞƚĂůͲŽŶͲŵĞƚĂů ŇĂŬŝŶŐ͕ ǁŚŝĐŚ ŵĂŬĞƐ ŝƚ ŝĚĞĂů ĨŽƌ ĂƉƉůŝĐĂƟŽŶƐ ƐƵĐŚ ĂƐ ĂƵƚŽŵŽƟǀĞ ďŽĚLJ ƐŚŽƉƐ ĂŶĚ ƉĂŝŶƚ ƐŚŽƉƐ͕͟ DŝnjĞŶ ƐƚĂƚĞƐ͘ dŚĞ ƐLJƐƚĞŵ ĚĞǀĞůŽƉĞĚ ďLJ ĞŵĂŐ WŽƌƚ ůŝnjĂďĞƚŚ ŚĂƐ ďĞĞŶ ƐƵƉƉůŝĞĚ ǁŽƌůĚǁŝĚĞ ĨŽƌ ŵĂŶLJ LJĞĂƌƐ͘ ͞dŚĞ ƋƵĂůŝƚLJ ŽĨ ƚŚĞ ƐLJƐƚĞŵ ŚĂƐ ŐĞŶĞƌĂƚĞĚ ŝŶǀĂůƵĂďůĞ ĞdžƉŽƐƵƌĞ

dŚĞ ^ŽƵƚŚ ĨƌŝĐĂŶ ĂƵƚŽŵŽƟǀĞ ŝŶĚƵƐƚƌLJ ŚĂƐ Ă ƐƉĞĐŝĮĐ ŶĞĞĚ ĨŽƌ ƌŽďƵƐƚ ĂŶĚ ŚĞĂǀLJͲĚƵƚLJ ůŝŶĞĂƌ ŽǀĞƌŚĞĂĚ ŵĂƚĞƌŝĂůƐͲŚĂŶĚůŝŶŐ ƐŽůƵƟŽŶƐ͘ D^ ŚĂƐ ďĞĞŶ ĚĞǀĞůŽƉĞĚ ƐƉĞĐŝĮĐĂůůLJ ĂƐ Ă ŵŽĚƵůĂƌ ƐŽůƵƟŽŶ ƚŽ ŵĞĞƚ ƐƵĐŚ ĐƵƐƚŽŵĞƌ ƌĞƋƵŝƌĞŵĞŶƚƐ͘ ͞tŚĞŶ ǁĞ ĚĞƐŝŐŶĞĚ ƚŚĞ ƐLJƐƚĞŵ ŝŶŝƟĂůůLJ ǁĞ ǁĞƌĞ ůŽŽŬŝŶŐ ƚŽ ĐĂƚĞƌ ĨŽƌ ŝŶĐƌĞĂƐĞĚ ƚŚƌŽƵŐŚƉƵƚ ŝŶ ƚĞƌŵƐ ŽĨ ĐLJĐůĞ ƟŵĞƐ͕ ǁŚŝůĞ ƚĂŬŝŶŐ ƐĂĨĞ ǁŽƌŬŝŶŐ ůŽĂĚƐ ŝŶƚŽ ĂĐĐŽƵŶƚ͕͟ ĞŵĂŐ ƉƌŽũĞĐƚ ĞŶŐŝŶĞĞƌ ĂŶĚ ƚĞĐŚŶŝĐĂů ƐĂůĞƐ ƌĞƉƌĞƐĞŶƚĂƟǀĞ EŝŬŝ DŝnjĞŶ ĐŽŵŵĞŶƚƐ͘ ͞KƵƌ ƐƵĐĐĞƐƐ ǁŝƚŚ ƚŚĞ ƐLJƐƚĞŵ ŽǀĞƌ ƚŚĞ 30

Lifting Africa - July/August 2015

DMS for robust heavy duty linear overhead materials handling solutions

Light crane system ĨŽƌ ƵƐ ŽŶ Ă ŐůŽďĂů ďĂƐŝƐ͘ dŚŝƐ ŝƐ Ă ƚŽƚĂů ƐŽůƵƟŽŶ ĨŽƌ ƚŚĞ ĂƵƚŽŵŽƟǀĞ ŝŶĚƵƐƚƌLJ ƚŚĂƚ ŚĂƐ ƐƚŽŽĚ ƚŚĞ ƚĞƐƚ ŽĨ ƟŵĞ͕͟ DŝnjĞŶ ĂĚĚƐ͘ ŶŽƚŚĞƌ ĨĞĂƚƵƌĞ ŽĨ D^ ŝƐ ƚŚĂƚ ŝƚ ĐĂŶ ďĞ ĨƵůůLJ Žƌ ƉĂƌƟĂůůLJ ĂƵƚŽŵĂƚĞĚ͘ ͞tĞ ĐĂŶ ƐƵƉƉůLJ Ă ƚŽƚĂů ƐŽůƵƟŽŶ ĨŽƌ ǁŚĂƚĞǀĞƌ ĐŽŵƉŽŶĞŶƚƐ ŶĞĞĚ ƚŽ ďĞ ƉŝĐŬĞĚ ƵƉ͕ for any end-products that need to be ƚƌĂŶƐƉŽƌƚĞĚ Žƌ ĂƐƐĞŵďůĞĚ͘ D^ ŝƐ ĨƵůůLJ ĐƵƐƚŽŵŝƐĂďůĞ ƚŽ ƵƟůŝƐĞ ƐƉĞĐŝĮĐ ďƌĂŶĚĞĚ ĐŽŵƉŽŶĞŶƚƐ ƌĞƋƵŝƌĞĚ ďLJ ƚŚĞ ĞŶĚͲƵƐĞƌ͕ ƐƵĐŚ ĂƐ ƐǁŝƚĐŚŐĞĂƌ ĂŶĚ W> Ɛ͘ /ŶĚƵƐƚƌŝĂů ǁŝƌĞůĞƐƐ ĐŽŵŵƵŶŝĐĂƟŽŶ ĂůůŽǁƐ ĨŽƌ ƐĞĂŵůĞƐƐ ŝŶƚĞŐƌĂƟŽŶ ďĞƚǁĞĞŶ ƚŚĞ ŚŽŝƐƚ ĂŶĚ ƚŚĞ ŵĂŝŶ ĐŽŶƚƌŽů ƉĂŶĞů͘͟ The fact that this is a modular system ŵĞĂŶƐ ŝƚ ŝƐ ŇĞdžŝďůĞ ĞŶŽƵŐŚ ƚŽ ĐĂƚĞƌ ĨŽƌ Ă ƌĂŶŐĞ ŽĨ ƉĂƌĂŵĞƚĞƌƐ͘ ^ƵĐŚ ŵŽĚƵůĂƌŝƚLJ ĂůƐŽ ĂůůŽǁƐ ĨŽƌ ĞĂƐLJ ƚƌĂŶƐƉŽƌƚĂƟŽŶ Žƌ ƐŚŝƉƉŝŶŐ ǀŝĂ ϭϮ ŵ ƐŚŝƉƉŝŶŐ ĐŽŶƚĂŝŶĞƌƐ͘ ͞dŚŝƐ ŝƐ Ă ƐŽůƵƟŽŶͲŽƌŝĞŶƚĂƚĞĚ ƐLJƐƚĞŵ ƚŚĂƚ ĐĂŶ ďĞ ĚĞƐŝŐŶĞĚ ƚŽ Įƚ ĂŶLJ ĨĂĐƚŽƌLJ ůĂLJŽƵƚ͕͟ DŝnjĞŶ ĐŽŶƟŶƵĞƐ͘ ͞KƵƌ ĐŽŶƐŝĚĞƌĂďůĞ ƐƵĐĐĞƐƐ ŝŶ ƚŚŝƐ ƌĞŐĂƌĚ ŚĂƐ ďĞĞŶ ĚƵĞ ƚŽ ƚŚĞ ĨĂĐƚ ƚŚĂƚ ǁĞ ŶŽƚ ŽŶůLJ ƐƵƉƉůLJ ƚŚĞ ďĞƐƚ ƐŽůƵƟŽŶ ĨŽƌ ŽƵƌ ĐƵƐƚŽŵĞƌƐ͕ ďƵƚ ƚŚĂƚ ǁĞ ĂƌĞ ĂďůĞ ƚŽ ŽīĞƌ Ă ƚŽƚĂů ƚƵƌŶŬĞLJ ƐLJƐƚĞŵ͕ ŝŶĐůƵĚŝŶŐ Ăůů ƚŚĞ ĐŽŶǀĞLJŽƌƐ ĂŶĚ ĂĐĐŽŵƉĂŶLJŝŶŐ ƐƚŽƌĂŐĞ ƌĞƚƌŝĞǀĂů ŵĂĐŚŝŶĞƐ͕͟ DŝnjĞŶ ŶŽƚĞƐ͘

The system uses polyurethane tyres to prevent metal-on-metal flaking

ĞŵĂŐ WŽƌƚ ůŝnjĂďĞƚŚ͛Ɛ ĮƌƐƚ ŵĂũŽƌ ŝŶƚĞƌŶĂƟŽŶĂů ĐƵƐƚŽŵĞƌ ǁĂƐ 'ĞŶĞƌĂů DŽƚŽƌƐ ŐLJƉƚ͘ ͞tŚĞŶ ƚŚĞ 'ĞŶĞƌĂů DŽƚŽƌƐ ŐůŽďĂů ŽƉĞƌĂƟŽŶ ŚĞĂƌĚ ǁŚĂƚ ǁĞ ŚĂĚ ĂĐŚŝĞǀĞĚ ŝŶ ^ŽƵƚŚ ĨƌŝĐĂ ƚŽ ĚĂƚĞ͕ ŝƚ ĚŝƌĞĐƚĞĚ Ă ƌĞĐĞŶƚ ĞŶƋƵŝƌLJ ĨŽƌ Ă ƐƉĞĐŝĮĐ ƐŽůƵƟŽŶ ĨƌŽŵ ƚŚĞ DŝĚĚůĞ ĂƐƚ ƚŽ ƵƐ͘ “This not only entrenches our repuƚĂƟŽŶ ĨŽƌ ƋƵĂůŝƚLJ ƚĞĐŚŶŽůŽŐLJ͕ ďƵƚ ĂůƐŽ

ĐŽŶƐŽůŝĚĂƚĞƐ ŽƵƌ ƉƌĞƐĞŶĐĞ ĂƐ Ă ŵĂũŽƌ ŝŶƚĞƌŶĂƟŽŶĂů ƉůĂLJĞƌ͘ dŚĞ ĨĂĐƚ ƚŚĂƚ ǁĞ ĐĂŶ ĐĂƌƌLJ ŽƵƚ ĐŽŵƉůĞƚĞ ƚƵƌŶŬĞLJ ƉƌŽũĞĐƚƐ ŵĞĂŶƐ ƚŚĂƚ ĞŵĂŐ WŽƌƚ ůŝnjĂďĞƚŚ ŝƐ ŝŶ ƚŚĞ ƵŶŝƋƵĞ ƉŽƐŝƟŽŶ ŽĨ ďĞŝŶŐ Ă ŽŶĞͲ ƐƚŽƉ ƐŚŽƉ͕͟ ŚĞ ĐŽŶĐůƵĚĞƐ͘ Demag Cranes, Wynand Andeweg Tel: (011) 898 3500 Email: enquiry.sa@terex.com www.demagcranes.co.za Lifting Africa - July/August 2015

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NEWS FROM AFRICAÚ

TC

In December 2015 the regrowth works of the Cambambe hydroelectric power station, in the Kwanza River, about 180 kilometres Southeast of Luanda, the capital of Angola, will be concluded. This dam currently supplies power to the cities of Luanda, Ndalatando, Cacuaco, Malanje, Gabela, Porto Amboim and Sumbe, benefiting a population of approximately 8 million people.

hree Linden omansa Tower Cranes At Cambambe Dam - Angola

uilt in 1962, the station is being renovated and expanded since 2009 to increase its energy production by 80%. From the current 180 MW per year, this infrastructure will then produce 960 MW, becoming the largest power production plant of the Kwanza basin. In 2014, Cambambe was certified with ISO 9001, 14001 and 18001 seals, being the first hydroelectric project in Africa to obtain such recognition.

B

Part of the project which is being conducted by the Brazilian construction company Norberto Odebrecht is the rise of the dam’s height by 20 metres. This heightening will increase the capacity of the reservoir from 2 to 5.5 km2, and allow the four existing generators to produce 65 megawatts each instead of the present 45.

In order to put into place the over 65,000 cubic meters of concrete needed to rise the dam, Odebrecht counts with the help of three Linden Comansa tower cranes: two 21LC750 with maximum load capacity of 48 tons acquired in 2012 32

Lifting Africa - July/August 2015

and a 21LC400 with maximum capacity of 18 tons leased by IBERGRU, the exclusive distributor of Linden Comansa in Angola.

The first 21LC750 was located on the left bank of the Kwanza River, erected with fixing angles on a special concrete foundation which, given its short width, was anchored to a rock on the river bank.

It was mounted with a freestanding height of 78.8 meters, the maximum possible height with 2.5-meter-wide mast sections (fourteen D36 sections), and a jib length of 80 meters.

On the right bank, a second 21LC750 was erected with a freestanding height of 87.2 meters, achieved with 12 sections D36 - as her "sister" in the left margin - increased by three 5-metre-wide D56 sections at its bottom. Another concrete foundation was anchored on the riverside to allow this crane’s assembly on fixing angles.

After a year and a half working in concreting and materials lifting tasks, the first 21LC750 (left bank) was relocated within the jobsite and substituted by a 21LC400

â&#x20AC;&#x153;This dam currently supplies power to the cities of Luanda, Ndalatando, Cacuaco, Malanje, Gabela, Porto Amboim and Sumbe

Lifting Africa - July/August 2015

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Lifting Africa - July/August 2015

NEWS FROM AFRICAĂ&#x161;

from IBERGRUâ&#x20AC;&#x2122;s rental fleet, which was erected with a freestanding height of 80 meters and a jib length of 70 meters. This crane was assembled on the same fixing angles of the previous 21LC750, so it was necessary to have two transition sections in order to allow the progression from the 4 meter-wide fixing angles to the 2.5-metre-wide D33 mast section.

The relocated 21L C750 is currently working on the construction of the power house (or power generation center) where it was assigned to moving precast segments up to 19 tons of weight for the new water tunnels, as well as lifting and placing all the electromechanical gear that will allow the production of energy, such as turbines and generator sets.

The assembly and jacking-up of the first 21LC750 was performed by Linden Comansaâ&#x20AC;&#x2122;s technical assistance service team, while the remaining assemblies, jack-

ing-ups and technical service was entrusted to IBERGRU. IBERGRU is the official distributor of Linden Comansa in Portugal since 2002. In 2008, the company opened offices in Angola, where it offers its tower crane rental services as well as technical planning and coordination for all kinds of lifting projects.

0DULDQR (FKiYDUUL

Email: mariano.echavarri@comansa.com www.comansa.com Lifting Africa - July/August 2015

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Lifting Africa - July/August 2015

M

A mobile crane owner has a multi-million Rand piece of equipment, with an operator doing multi-million Rand lifts.

jobsite – from personnel to weather to surroundings.

6.

Sometimes in a working situation, the crane operator needs to stop, evaluate, and find a safer lift plan.

As an owner and operator you should and the customer believes that you know the best way to lift their particular item and the safest way as well.

7.

Check ground conditions – before crane setup, ensure that the site is suitable to support your mobile crane and the future suspended loads.

In the ever-changing world of Mobile Crane Operations, it is more important than ever to stay up-to-date with the regulations as well as best practices.

8.

Use appropriate pads & cribbing – mobile crane operators need to make sure they are using correct pads or cribbing to avoid having an outrigger fail or sink when they are making a lift.

9.

Before starting your crane, always double check the oil, gas, and other fluid levels (maintenance of the cranes are everyone’s lively hood and success).

10.

At the beginning of your shift, walk-around your crane checking for mechanical, electrical, structural, and hydraulic issues (MESH).

Here are 10 tips you can use to help ensure success:

1.

2.

Never override the mobile crane’s computer.

3.

Read the load charts – prior to turning the key in any new mobile crane.

4.

Cell phones in the cab – while the crane’s key is on the cell phone is off. (preferably no cell phones in the cab at all times).

5.

Always note the changing conditions on the

Be aware of all overhead hazards – specifically close-by buildings and any power lines that are within the working zone of operation.

Lifting Africa - July/August 2015

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HEALTH & SAFETYÚ

10 Good Tips For obile Crane Operations

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39

EXPORTSÚ

R C

ugged Reliability A Boost to rane Exports

South African crane manufacturer Condra has reported an increase in exports to Canada, the result of increasing awareness of product capabilities in that country.

The company’s agent in Saskatchewan believes that Canadian engineers are gradually accepting the long term advantages of install-

Condra units being crated for export 40

Lifting Africa - July/August 2015

ing robust, durable cranes instead of the more delicate machines of some northern hemisphere manufacturers.

Orders mainly comprise hoists up to 60 tons, overhead cranes up to 40 tons, and spares, delivered predominantly to customers in mining.

Although the Canadian export increment is small as a percentage of total manufacturing volume, the upward trend is seen as significant by management.

Condra entered the Canadian mar-

ket at the beginning of 2011 in response to initial orders from expatriate South African engineers familiar with Condra’s combination of a rugged, reliable and robust hoist and crane design enhanced by innovative drive and control technology to deliver an impressive overall capability.

In the same year, a local agent was appointed to manage sales, installation and servicing across the product range.

Over the four years since, word of the reliability of these South African manufactured machines has spread beyond the expatriate engineering fraternity, mainly because the cranes continue to work in hostile mining environments when their European and American equivalents have broken down because of skipped services.

The Condra service interval is generally longer than those of competitors’ machines.

Modular design Condra’s technology is based on modular design, an approach

which allows application flexibility without a disproportionate increase in price to the end-user.

An example of this is the use of standard hoists as a platform from which modifications to customer specification can be accommodated. For high-lift applications, the company regularly adapts units to deliver a 15-metre lift, more than twice the average lift height of 6,8 metres.

Condra’s mandate to continually drive down product maintenance costs is ongoing, two examples being the use of live-axle drives in place of ring-gear designs, and the introduction of adapted V-belt technology which has already been tested and proven in the motor vehicle industry.

In this way, the total cost of the crane over a typical useful life is lowered.

Extending crane lifespan For some years now, Condra has incorporated very high quality materials in component manufacture.

Gearboxes have been up-rated to deliver additional power, and the company is using a 36B case-hardened material on most pinions.

This material, though expensive, is

Hoists mounted on crab unit

“South African engineers deliver an impressive overall capability” beneficial in extending crane lifespan.

Hoists are also usually fitted with high tensile-strength ropes. The resulting reduction in rope diameter enables use of a reduced drum diameter and a smaller gearbox and

motor, all of which help contain costs.

Compliance with ISO and other international quality standards have also helped Condra to drive export sales to Canada.

Company management expects high product quality, lower maintenance costs and lower overall useful lifetime costs to continue to contribute to Condra’s sustainable competitive advantage in markets worldwide.

Condra (Pty) Ltd, Marc Kleiner Tel: (011) 776-6000 E-mail: sales@condra.co.za

Searle S earrle strip strii 2

Lifting Africa - July/August 2015

41

PRODUCTS & SERVICESÚ

T

he Power of Vacuum

In the old days it was a case of many hands make light work, while this remains true, technology today makes even lighter work, thereby increasing productivity and reducing costs.

I

n the blockbuster movie,” Mission Impossible: Ghost Protocol”, there is a scene where Ethan, played by Tom Cruise, climbs the side of the world's tallest building, the Burj Khalifa, using a pair of gecko-like suction gloves. Was this fantasy or reality?

In the Myth buster’s 54th episode, presenters Adam and Jamie proved that this was no myth. Adam climbed an air duct using Suction Cups. Not to be outdone, the BBC’s Bang Goes the Theory presenter, Jem, scaled the side of the aluminium cladded BBC building using ‘Spiderman’ style vacuum gloves. Inspired, a 15-year old Cambridge schoolboy did the same thing, but on a brick-faced building, and used two domestic vacuum cleaner motors. Until these events took place, it was believed impossible.

“Vacuum lifters are perfect solutions for wood handling on the factory floor” Moving to the factory floor, the same spider-like technology exists, not for climbing but for lifting. In South Africa vacuum lifting technology is relatively new. However, in the USA, Europe and the Far East, vacuum lifting equipment is widely used in many industrial sectors for the lifting and handling of materials/components that have a flat or smooth surface. In particular materials such as metal, glass, concrete slabs, pipes, plaster boards, plastic laminates, cement 42

Lifting Africa - July/August 2015

bags, beer kegs and so on. These products can be easily lifted and handled using vacuum lifting equipment fitted with suction pads that attach to and lift loads as much as 45 000 kg in weight, and more. No doubt the usual sceptics will say this is impossible. The pictures below tell a different story.

There are two basic types of vacuum lifting equipment: Vacuum lifting tubes (VLT): A lifting system, a machine, incorporating a vacuum tube with suction pads used for both gripping and lifting the load.

Vacuum lifting attachments (VLA): A detachable lifting attachment incorporating suction pads that is fixed to an independent lifting machine (eg, attachment to a crane or hydraulic excavator arm or

The South African connection forklift truck. The attachment is used for gripping the load and the machine used to lift the whole assembly.

The difference between a VLT and a VLA is that VLT is used for both gripping and lifting the load, but a VLA functions as an attachment for just gripping a load and not lifting it.

The advantages of vacuum lifting and material handling technology are: •

Fast and simple handling: The vacuum’s sucking and releasing steps only need a few seconds to complete activation.

•

Reduction of production costs: Higher productivity is achieved through the use of this fast, easy to use technology that requires less man power and that has a lower energy consumption rate.

•

Reduced wastage: No matter the load, this technology causes no damage, such as scuffing or grazing.

•

Safety first: With double safety factors giving a reliable safety provisions even in the case of power failures/load shedding.

Sheet metal handling Moving sheet metal is usually a challenging process, with much care needed. Using the more traditional methods, one simple error and a slipped sheet can cut a man in half. Thinner sheets have proved particularly difficult to handle due to lower intrinsic stability. Even large sheets can be quickly picked up and moved, over long distances, to the next phase in the production process.

The simplicity, with which the vacuum lifter can be operated, with an adjustable, angled handle and one

As with everything, manufacturing quality, reliability, service and support are critical. The Aero-Lift range of vacuum lifters, which are manufactured in Germany by Aero-Lift Vakuumtechnik GmbH, are represented in South Africa by WH Lifting & Handling CC. Werner Hurlimann, founder and technical director at WH Lifting & Handling CC, and originally from Switzerland but now proudly South African, said, “We expect vacuum lifting to take-off in South Africa as it really is a solidly engineered technology that can bring huge productivity gains to a ranges of businesses where material handling plays an important role.

More over, we have been in South Africa for the last 20-years and have built up a substantial skills base in order to provide a first-class installation and maintenance support service.”

hand, makes sheet metal handling a breeze. Warping or even bending of the transported sheet metal is avoided through proper configuration of the suction plates to suit the dimensions involved. Depending on the application, each sheet metal vacuum lifter is classified according to its maximum load and load frequency. A pivoting range of 90o gives the vacuum lifter the Lifting Africa - July/August 2015

43

PRODUCTS & SERVICESÚ

others makes no difference. A high-performance blower sorts this out. With a maximum size of 7 m x 2.1 m and/or 500 kg, coupled with the single-handed operation, vertical pivot and horizontal turning capabilities, the vacuum lifter is the perfect wood handling tool. Be it in a sawmill, warehouse or furniture factory, or on a construction site, handling of heavy joists, planks, wood laminate beams or block planks is made simple, fast and reliable, without machine damaging the wood.

Handling wood, without damaging the wood, has never been easier

flexibility needed in a typical production environment.

If needed, a vacuum lifter can be fitted with an 180o horizontal turning capability.

Whether the sheet metal is being used to manufacture air ducts or big ships, handling light to very heavy metal loads is no longer a cumbersome process. Even lifting and placing IBR roof sheeting is made simple. The reliable traversing system, intelligent suction plate configuration, with all components manufactured to the highest quality standards, ensures a safe, stable and yet quick mechanism to transport sheet metal to where it is needed.

A rather interesting application is the box module, for finished products such as preassemble parts, cabinets, housings and boxes. This module gently grabs the piece on each side and transports it further. Another ingenious development is the VUSS vacuum gripper that enables the vacuum pads to lift a board despite any milled-out portions. A vacuum is only created in areas where there is wood flush. The vacuum lifter can be used in conjunction with a pillar-mounted slewing crane, articulated arm jib, rail system or electric chain hoist.

Other applications Cladding, window repairs, roofing and window fitting has never been easier either. Tailor-made variations of VLT and VLA vacuum lifters can be used for a myriad of applications, even in glass-clad high-rise building construction using UV-resistant suction plates. Electricity mains-free versions for cladding and construction are also available.

With companies such as Group 5, Bell Equipment, MacSteel and TFM already using vacuum lift technologies from Aero-Lift in their day-today manufacturing processes, they obviously don’t doubt the capabilities of this amazing technology. Clearly, Ethan Hawk’s antics with vacuum power are no longer the realm of movie fantasy. It’s time to be stuck onto real power.

WH Lifting, Tel: (011) 315-0227

Multiple, uniform suction cups make it easy to move sheet metal

Wood handling Wood is an extremely sensitive material that must always be handled with care. Scratches and damage ultimately spoil the product. Vacuum lifters are perfect solutions for wood handling on the factory floor, be this chip board or solid wood – because this technology is wood friendly.

The fact that some woods are more porus than 44

Lifting Africa - July/August 2015

Newcorr Mining and Industrial is privately owned, registered with the Department of Labour as a Lifting Machinery Entity, with ECStA registered Lifting Machinery Inspectors. We have offices and well-established repair facilities in Gauteng and Mpumalanga.

inspection, repair and cercerrdancce c to o tification in accordance is service se e vice erv e DMR Reg. 18. This e s iss ets is required in all marke markets porta a ce. anc one of great importance. dling gb eWith material handling beor contr ttrib ibut ib utor torss to to ssaf afet a af afety fety-re ety rel re ellated ated injuinju ing one of the major contributors safety-related ries, there is a statutory framework which all End-Users are required to abide by.

e supply, service, re-condition, conduct on-site inspections, provide and maintain asset/inspection registers for Lifting Tackle and Machinery as well as offer training in Safe Care & Use of Lifting Equipment.

The on-site proof load testing service is quite unique to Newcorr. This expedites the procedure between inspection and certification, therefore reducing down time, minimizing equipment failure. It also ensures that none of the equipment leaves the customer’s premises. Part of our management of Lifting Equipment program is supported by additional materials such as Colour code boards, inspection point boards and colour coded tags.

We provide a holistic approach to lifting equipment in the mining, petrochemical, construction and engineering markets. From the supply of fully traceable products compliant to National and International standards, to

Newcorr Mining & Industrial, Lynda Lake Gauteng, Tel: (011) 392-5855/7, Adam © 084 366 3395 or Lynda © 082 786 1507.

Mpumalanga, Kriel, Tel: (017) 648-2736/40, Tyron © 079 527 6650 or Barry © 082 853 7744. www.newcorrliftingsolutions.co.za

W

Lifting Africa - July/August 2015

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PRODUCTS ODUCTS ODUCT TS & SERVICESÚ SERVICES

L

ifting Solutions Specialists

REGULATIONSÚ

D

riven Machinery Regulations, 2015 - Gnr.527 of 2015

Definitions In these Regulations, “the Act” means the Occupational Health and Safety Act, 1993 (Act No. 85 of 1993), and any word or expression to which a meaning has been assigned in the Act shall have the meaning so assigned, and, unless the context otherwise indicates - “bench saw” means a circular saw working in a bench (including a rack-bench) for the purpose of ripping, deep cutting or cross cutting, but does not include a swing-saw or other saw that is moved towards the wood; “block and tackle” means a lifting device consisting of one or more pulley blocks reeved with fibre ropes, used solely for the raising and lowering of a load or for moving it horizontally, but does not include chain blocks, lever hoists or steel- wire rope pullers; “calender rolls” means a series of counter -rotating rollers at the end of a rolling process “capstan-type hoist” means a rotating machine

Take note that in terms of DMR24, these Regulations will take effect on 30 September 2015.

used to control or to apply force to move or raise loads by traction on a rope or cable; “competent person” means a person who has the knowledge, training, experience and qualifications specific to the work performed: Provided that where appropriate qualifications and training are registered in terms of the provisions of the South African Qualifications Authority Act, 1995, those qualifications and that training shall be deemed to be the required qualifications and training; “hand-powered lifting device” means a lifting device consisting of one or more sheave components reeved with chains, steel rope or fibre ropes, used solely for the raising and lowering of a load or for moving it horizontally and includes chain blocks, lever hoists, hand chain hoists, steel-wire rope pullers and winches, but does not include hand-powered hydraulic lifting devices; “lifting machine” means a power-driven machine that is designed and constructed for the purpose of raising or lowering a load or moving it in suspension, but does not include an elevator, escalator or hand-powered lifting device; “lift truck” means a mobile lifting machine, but does not include: a. a vehicle designed solely for the purpose of lifting or towing another vehicle; b. a mobile earth -moving machine; or c. a vehicle designed solely for the removal of a waste bin; “lifting machinery entity” means a legal entity approved and registered by the chief inspector in terms of regulation 19; “lifting machinery inspector” means a person who is employed by a Lifting Machinery Entity and who is registered by the Engineering Council of South Africa in terms of the Engineering Profession Act, 2000 (Act No. 46 of 2000);

46

Lifting Africa - July/August 2015

“transportation plant” means apparatus used for the transportation of material by means of an elevated conveyance suspended from and travelling along a catenary rope or chain where persons may pass or work below the path of the conveyance, or any such apparatus used for the transportation of persons.

Scope of Application These Regulations shall apply to the design, manufacture, operation, repair, modification, maintenance, inspection, testing and commissioning of driven machinery.

Revolving Machinery Unless moving or revolving components of machinery are in such a position or of such construction that they are as safe as they would be if they were securely fenced or guarded, the user shall cause: “lifting tackle” means chain slings, wire rope slings, woven webbing slings, master links, hooks, shackles and swivels, eye bolts, lifting or spreader beams, tongs, ladles, coil lifters, plate lifting clamps and drum lifting clamps used to attach a load to a lifting machine; “load path” means all the parts of the lifting machine under stress during the lifting operation; “man-cage” means a platform enclosed on all sides, whether closed or open at the top, designed for the purpose of raising and lowering persons by means of a lifting machine, but does not include mobile elevated work platforms and suspended access platforms; “point of operation” means that place in a machine where material is positioned and where the actual work is performed; “press” means a driven machine that shears, punches, forms or assembles metal or other material by means of cutting, shaping or combination dies attached to slides having a controlled reciprocating motion, but does not include bending brake presses, hot bending or hot metal presses, forging hammers and riveting machines or similar types of fastener applicators; “safe working load” means the mass load applicable to a piece of equipment or system as determined by a competent person taking into account the environment and operating conditions; “thorough examination” means examination or inspection to determine whether the equipment is safe to use; “training provider” means a training provider for lifting machinery operators approved and registered by the chief inspector in terms of regulation 20;

a. every shaft, pulley, wheel, gear, sprocket, coupling, collar, clutch, friction drum or similar object to be securely fenced or guarded; b. every set screw, key or bolt on revolving shafts, couplings, collars, friction drums, clutches, wheels, pulleys, gears and the like to be countersunk, enclosed or otherwise guarded; c. every square projecting shaft or spindle end and every other shaft or spindle end that projects for more than a quarter of its diameter to be guarded by a cap or shroud; d. every driving belt, rope or chain to be guarded; and e. The underside of every overhead driving belt, rope or chain above passages or workplaces to be so guarded as to prevent a broken belt, rope or chain from falling and so injuring persons: Provided that the provisions of this paragraph shall not apply where, in the opinion of an inspector, no danger exists in the case of light belts owing to the nature thereof and the speed of operation.

Lifting Machines, Hand-Powered Lifting Devices And Lifting Tackle (1) No user may use or permit the use of a lifting machine or hand-powered lifting device unless: a. it has been designed and constructed in accordance with a generally accepted technical standard; b. it is conspicuously and clearly marked with the safe working load: Provided that when such safe working load varies with the conditions of use of the manufacturer, a table showing the safe working load with regard to every variable condition shall be posted by the user in a conspicuous place easily visible to the operator; c.

the manufacturer’s identification plate displayLifting Africa - July/August 2015

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ing the name of the manufacturer, the design standard, the serial or reference number and the country of origin is affixed to such machine; and

ered lifting device, as well as ancillary lifting equipment used with the machine or device, excluding lifting tackle, to be subjected to a thorough examination and a performance test, as prescribed by the standard to which the lifting machine was manufactured, by a lifting machinery inspector of a lifting machinery entity, which shall determine the serviceability of the structures, ropes, machinery and safety devices before they are put into use and every time they are dismantled and re- erected, and thereafter at intervals not exceeding 12 months: Provided that, in the absence of a manufacturing standard or a standard incorporated under section 44(1) of the Act, the whole installation of the lifting machine shall be tested with 110% of the safe working load applied over the complete lifting range of such machine and in such a manner that every part of the installation is stressed accordingly.

d. it has at all times at least three full turns of rope on the drum of each winch that forms part of such a machine when such winch has been run to its lowest limit, and that is controlled by an automatic cut -out device: Provided that paragraphs (b) and (d) above shall not apply to capstan-type hoists (2) The user shall ensure that every power-driven lifting machine is fitted with a brake or other device capable of holding the safe working load should: a. the power supply or lifting effort fail; b. the load attachment point of the power-driven lifting machine reach its highest and lowest safe position; or c. the load condition be greater than the rated load condition of that machine.

b. The lifting machinery inspector of the lifting machinery entity referred to in paragraph (a) must have knowledge of the erection, load-testing and maintenance of the type of lifting machine or similar machinery involved. c.

Notwithstanding paragraph (a), mobile cranes, self-erecting cranes and mobile elevated work platforms shall be excluded from the performance test after each re- deployment within the 12-month period referred to in that paragraph.

(6) Notwithstanding subregulation (5), the user shall cause all ropes, chains, hooks or other attaching devices, sheaves, brakes and safety devices forming an integral part of a lifting machine or hand-powered lifting device to be subjected to a thorough examination by a competent person at intervals not exceeding six months.

(7)

(3) The user shall cause every chain or rope that forms part of the load path of a lifting machine or hand-powered lifting device to have the factor of safety prescribed by the standard to which that machine was manufactured. Provided that in the absence of such prescribed factor of safety, chains, steel-wire ropes and fibre ropes shall have a factor of safety of at least four, five and 10, respectively, with regard to the safe working load of that machine.

(4) The user shall cause every hook or any other loadattaching device that forms part of the load path of a lifting machine or hand-powered lifting device to be so designed or proportioned that accidental disconnection of the load under working conditions cannot take place.

(5) a. The user shall cause the entire installation and all working parts of every lifting machine or hand-pow48

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a. Every user of a lifting machine or hand-powered lifting device shall at all times keep on their premises a register in which the user shall record or cause to be recorded full particulars of any performance test and examination referred to in subregulations (5) and (6) and any modification or repair to such lifting machine or hand-powered lifting device, and shall ensure that the register is available on request for inspection by an inspector. b. Every user of a leased lifting machine or hand-powered lifting device shall at all times keep on their premises a register in which the user shall have the latest applicable performance test and service records not older than 12 months. c.

The owner and the lessor of leased equipment shall keep and maintain full service history records on their premises for at least 10 years.

(8) No user shall require or permit any person to be moved or supported by means of a lifting machine unless that machine is fitted with a man-cage designed and manufactured according to an approved SANS standard approved for that purpose by an inspector

and after a risk assessment has been done.

(9) No user shall use or permit any person to use any power-driven lifting machine unless it is provided with: a. in the case of a power-driven lifting machine with a lifting capacity of greater than 5 000 kg, a load indicator capable of indicating to the operator of the machine the mass of the load being lifted: Provided that such device shall not require manual adjustment, from the application of the load to the power-driven lifting machine until the release of that load, using any motion or combination of motions permitted by the crane manufacturer to ensure safe lifting; and /or

(ii) seven for man -made fibre ropes or woven webbing; (iii) six for steel-wire ropes, except for double -part spliced endless sling legs and double -part endless grommet sling legs made from steel-wire rope, in which case the factor of safety shall be at least eight; (iv) five for steel chains; and (v) four for high -tensile or alloy steel chains: Provided that when the load is equally shared by two or more ropes or chains the factor of safety may be calculated in accordance with the sum of the breaking strengths taking into consideration the angle of loading; d. all lifting tackle is inspected and discarded if such items show any sign of damage, defect, wear or distortion that would make them unsafe for use, as per manufacturerâ&#x20AC;&#x2122;s specification; and e. such lifting tackle is examined at intervals not exceeding three months by a competent person, appointed by the user in writing for this purpose, who shall record and sign results of such examination.

b. a load- limiting device that will automatically arrest the driving effort whenever the load being lifted is greater than the safe working load of the power-driven lifting machine at that particular radius, using any motion or combination of motions permitted by the crane manufacturer to ensure safe lifting: Provided that such device shall not arrest the driving effort when the power-driven lifting machine is being operated into a safer position: Provided that power-driven lifting machines manufactured or refurbished prior to the commencement of these Regulations shall be deemed to comply with these Regulations.

(10) No user may use or allow the use of any lifting tackle unless: a. every item of lifting tackle is well constructed of sound material, is strong enough, is free from defects and is constructed in accordance with a generally accepted technical standard; b. every lifting assembly consisting of different items of lifting tackle is conspicuously and clearly marked with traceable identification particulars and the safe working load that it is designed to lift with safety; c.

the ropes, chains or woven webbing have a factor of safety with respect to the safe working load they are designed to lift; the safety factor being: (i) 10 for natural -fibre ropes;

(11) The user shall ensure that every lifting machine is operated by an operator specifically trained for that particular type of lifting machine: Provided that in the case of a lifting machine listed in the National Code of Practice for Training Providers of Lifting Machine Operators, the user shall not require or permit any person to operate such a lifting machine unless the operator is in possession of a certificate of training, issued by a training provider accredited by the Transport Seta approved for the purpose by the chief inspector.

Approval and Registration of Lifting Machinery Entity (1) The chief inspector may approve any legal entity that has the competency and operational ability and that is involved in the examination and performance- testing of lifting machines, hand-powered lifting devices and ancillary lifting equipment used with the machine or devices.

(2) An application for approval and registration as a lifting machinery entity shall be made to the chief inspector in the form of Annexure A. (3) The chief inspector shall furnish an approved lifting machinery entity with the appropriate certificate of registration and shall enter such registration into the national database.

(4) An approved lifting machinery entity shall on request produce a certificate of registration to an inspector or to any person to whom it intends to render an examination or performance test.

(5) An approved lifting machinery entity shall inform the chief inspector of any change affecting its approvLifting Africa - July/August 2015

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al and registration under these Regulations within 14 days of such change.

Approval and Registration of Training Providers

b. set out the grounds for appeal.

(6) After considering the grounds for appeal and the chief inspector’s reasons for their decision, the Director-General: Labour shall confirm, set aside or amend the decision as soon as practicable.

(1) The chief inspector may approve and register any training provider that has been accredited by the Transport Education and Training Authority as an approved training provider.

(2) An application for approval and registration as a training provider must be made to the chief inspector in writing and must be accompanied by: a. a certified copy of the accreditation letter issued by the Transport Education and Training Authority; and b. a cancelled company letterhead.

(3) The chief inspector shall furnish an approved training provider with the appropriate certificate of registration and enter such registration into the national database.

(4) An approved training provider shall inform the chief inspector of any change affecting its approval and registration under these Regulations within 14 days of such change.

Withdrawal of Approval and Registration of Lifting Machinery Entity or Training Provider (1) Subject to subregulation (2), the approval and registration of a lifting machinery entity or training provider may be withdrawn if: a. a lifting machinery entity no longer has the necessary competency or operational ability; b. a training provider is no longer accredited by the Transport Education and Training Authority; or c. they are convicted of an offence referred to in regulation 22.

(2) The chief inspector may not withdraw an approval and registration unless: a. the holder of such approval and registration has been informed of the intended withdrawal and of the grounds upon which it is based; and b. such holder has been afforded a reasonable opportunity to make representations.

(3) The chief inspector shall inform the holder concerned in writing of the reasons for the decision.

(4) Any holder adversely affected by a decision of the chief inspector may appeal in writing to the Director-General: Labour against such decision.

(5) An appeal referred to in subregulation (4) shall: a. be lodged within 60 days from the date on which the decision was made known; and 50

Lifting Africa - July/August 2015

Offences and Penalties Any person who contravenes or fails to comply with any of the provisions of regulations 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17(1), 17(2), 17(5), 17(6), 17(7), 18, 19(4), 19(5), 20(4) and 20(5) shall be guilty of an offence and liable upon conviction to a fine or to imprisonment for a maximum of 12 months and, in case of a continuous offence, to an additional fine not exceeding R200,00 or to additional imprisonment of one day for each day on which the offence continues: Provided that the period of such additional imprisonment shall not exceed 90 days.

Repeal of Regulations and Transitional Provisions (1) The Driven Machinery Regulations, 1988, and subsequent amendments are hereby repealed.

(2) A user of a goods hoist as provided for in regulation 17 of the Regulations referred to in subregulation (1) above shall within five years of the publication of these Driven Machinery Regulations comply with the provisions of the Lift, Escalator and Passenger Conveyor Regulations, 2010, in which “Access Goods only Lift” is defined.

Short Title and Commencement These Regulations shall be called the Driven Machinery Regulations, 2015, and shall come into effect on 30 September 2015. (see more in our next issue)

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Lifting Africa - July/August 2015