General Questions
Revised December 2006
Working load limit (WLL) in the past was referred to as safe working load (SWL) for slings and lifting gear only. WLL is now used when there are no conditions imposed on the sling (example, direct lifting). SWL is used when there are conditions imposed on the sling (example, reeving, backhooking and angles between sling legs).
SECTION A: SLINGS (Chain, Wire rope, Fibre rope, Synthetic)
1. What is the formula or "rule of thumb” for determining the working load limit (WLL) of an unidentified synthetic rope?
2. Calculate the working load limit (WLL) of one of the following:
(i) 12 mm diameter unidentified Synthetic rope
(ii) 15 mm diameter unidentified Synthetic rope
(iii) 20 mm diameter unidentified Synthetic rope
3. What is the smallest size diameter synthetic rope allowed for load lifting purposes?
4. What is the smallest size diameter fibre rope allowed for use as a hand-
5. What will condemn a fibre rope from safe use for lifting purposes? List at least six defects.
6. What is the maximum temperature that a fibre rope can be exposed to before it is unsafe for lifting purposes?
7. Is it safe to use slings to raise or lower loads near or over people?
8. How is the working load limit (WLL) determined for synthetic webbing slings?
9. What factors should be considered when inspecting synthetic webbing slings for safe use? List at least six points.
10. When should a synthetic webbing sling be discarded? List at least six points.
11. List at least three requirements for the safe storage of synthetic webbing slings.
12. What is the “rule of thumb” formula used to calculate the WLL of a flexible steel wire rope (FSWR)?
13. Calculate the WLL of one of the following:
(i) 15mm diameter FSWR.
(ii) 20mm diameter FSWR.
(iii) 25mm diameter FSWR.
14. What is the minimum allowable size FSWR for load handling purposes?
15. What is the maximum allowable temperature that FSWR can be exposed to before it is unsafe for lifting purposes?
16. What is the formula that indicates the maximum amount of broken wires permitted in FSWR?
17. Using the formula for maximum amount of broken wires permitted in FSWR for lifting
purposes, work out one of the following: -
(i) The construction of rope is 6/19 and 12 mm diameter.
(ii) The construction of rope is 6/24 and 20 mm diameter.
(iii) The construction of rope is 6/36 and 54 mm diameter.
18. What is meant by the term "Core Slippage"?
19. What will condemn a FSWR sling from safe use? List at least six defects.
20. What is the "rule of thumb" formula for calculating the WLL for a grade 80 high tensile chain?
21. Calculate the WLL of grade 80 high tensile chain for one of the following diameters:
(i) 10 mm
(ii) 12 mm
(iii) 15 mm
22. What is the smallest size diameter chain allowable for safe load handling for:
(i) Grade 30 chain
(ii) High tensile grade 80 chain
23. What is the maximum temperature that a sling can be subjected to before the SWL is affected for:
24. What will condemn a chain from safe use? List at least four defects.
25. What is the maximum amount of wear permitted in the link of a chain?
26. Where on a chain link is wear most likely to occur? List two points.
27. What action would you take if a chain has:
(i) No WLL tag?
(ii) No WLL tag & grade marking?
28. What does the marking on a link of a chain indicate?
SECTION B: SHEAVES AND DRUMS
29. What will condemn a sheave from safe use? List at least three defects.
30. List two effects "double blocking" can have on the crane and equipment.
31. When the rope construction is unknown, what is the “rule of thumb” method used to calculate a sheave size?
32. How much of the FSWR should sit neatly in the base of the groove of a sheave?
33. How deep must the sheave groove be in relation to the rope diameter been used?
34. When the maximum number of turns is wound on a drum, how far must the flange of the drum extend above the outer layer of rope?
35. What is the advantage of using a jockey sheave?
36. What will occur if the sheave groove is too large for the diameter of the given rope?
37. What will occur if the sheave groove is too small for the diameter of the given rope?
38. How is the diameter of a sheave measured?
39. When the hook or the block is at the lowest possible point, what is the minimum amount of full turns of
wire rope that must remain on the winch drum?
40. What happens if the fleet angle of the hoist rope is incorrect?
41. What problem would occur if the jockey sheave seized?
__________________________________
SECTION C:
ROPE TERMINATIONS, ANCHORS AND ATTACHMENTS ASSOCIATED DURING LIFTING OPERATIONS
42. Why must you pack/lag the edges/corners of sharp loads?
43. How can the lifting capacity of a hook be identified?
44. What are the approved methods of fixing the hoist wire to the boom head? List two methods.
45. What may be fitted (where applicable) to the hook to prevent the slings from dislodging?
46. If the hook spins rapidly what may it indicate? List two examples.
47. List two methods used to secure/fix the tail of the hoist rope to the winch drum.
48. From the diagrams below, select the correct methods of reeving a hoist rope in a wedge rope socket.
49. Are you permitted to use wire rope (bulldog) grips to connect two lengths of wire rope for lifting purposes? Explain your answer.
50. Explain the use and advantages of a wire rope thimble?
51. Name the two principal shapes of shackles.
52. What must be marked on a shackle to be used for load handling?
53. Which type of shackle should be used for multi-
54. Why is it unsafe to interchange components of a shackle?
55. Name two types of lifting eye bolts.
56. Is it permissible to reeve a sling through two or more eyebolts and what effect does this have on the eyebolts?
57. Which type of eye bolt should be used for lifts where the pull on the sling is off centre to the axis of the eye bolt?
58. Select the correct method of using eyebolts with a two-
59. What precautions should be taken when using a single eyebolt for lifting?
.
60. What advantage does a swivel fitting provide?
61. Why is it important to mouse a lifting hook or seize the pin of a shackle?
62. What should a lifting ring and the slings attached to it have in common?
63. What defects can occur in lifting rings, eye-
64. If a lifting ring or shackle is placed on a hook and it does not hang freely what does this indicate?
65. To what amount can the beak / bill of a hook be stretched before it is condemned?
.
66. What will condemn a hook from use? List two defects.
67. Should the wedge protrude outside the narrow end of the socket fitting? (as in the diagram)
68. What is the minimum amount of tail projection for the dead end of a rope used with a wedge socket?
69. What should be secured to the tail of a rope when in use with a wedge socket fitting, to indicate slippage?
70. Explain the reason for using a swaged aluminium alloy fitting or a thimble fitting.
71. What is the most obvious indication, of a defective swage fitting?
72. What details are displayed on a spreader-
SECTION D OPERATIONAL MANUAL
73. A sling of 2.0 tonnes WLL is reeved around a circular load. What is the sling now capable of lifting?
74. A sling of 8.0 tonnes WLL is reeved around a circular load. What is the sling now capable of lifting?
75. A sling of 4.0 tonnes WLL is reeved around a circular load. What is the sling now capable of lifting?
76. A sling of 6.0 tonnes WLL is reeved around a circular load. What is the sling now capable of lifting?
77. A sling of 5.0 tonnes WLL is reeved around a square load. What is the sling now capable of lifting?
78. A sling of 4.0 tonnes WLL is reeved around a square load. What is the sling now capable of lifting?
79. A sling of 3.0 tonnes WLL is reeved around a square load. What is the sling now capable of lifting?
80. A four (4) legged bridle sling arrangement is attached to a rigid load. How many and which sling legs would be assumed to support the load?
81. A three (3) legged bridle sling arrangement is attached to a rigid load. How many sling legs would be assumed to support the load?
82. A four (4) legged bridle sling arrangement is attached to a flexible load. How many sling legs would be assumed to support the load?
83. A sling of 1.5 tonnes WLL, is used in basket hitch around a square load. What is the sling now capable of lifting?
84. A sling of 1.5 tonne WLL is reeved around a square load. What is the sling now capable of lifting?
85. A lifting beam with a mass (weight) 300 kg is supported by a two legged sling shackled to the beam forming
an included angle of 90 degrees at the crane hook. See diagram two slings are shackled to the underside of the lifting beam and vertically down to lifting eyes on a machine of mass 2,500 kg. What is the minimum SWL required?
86. If two slings are spread at an included angle of 90 degrees, what is the load factor applied to the load been lifted?
.
87. If two slings are spread at an included angle of 30 degrees, what is the load factor applied to the load been lifted?
88. If two slings are spread at an included angle of 60 degrees, what is the load factor applied to the load been lifted?
89. If two slings are spread at an included angle of 120 degrees, what is the load factor applied to the load been lifted?
90. From the drawings below select the included angle closest to 90 degrees.
91. What reduction must be made to the WLL of a FSWR sling when it is reeved on a round load?
92. What reduction must be made to the WLL of a FSWR sling when it is reeved on a square load?
93. What safety factor must be applied to the WLL of a FSWR sling when a basket hitch is used to cradle a square load?
94. What safety factor must be applied to the WLL of a FSWR sling when a basket hitch is used to cradle a round load?
SECTION E LOAD ASSESSMENT
95. What is the weight of a 25mm thick steel plate 3 metres long x 2 metres wide?
Note: Structural steel weighs 7,840 kg per cubic metre. Answer to be provided in KILOGRAMS.
96. What is the weight of a 25mm thick steel plate 3 metres long x 3 metres wide?
Note: Structural steel weighs 7,840 kg per cubic metre. Answer to be provided in KILOGRAMS.
97. What is the weight of a 1.5 cubic metre concrete skip filled with concrete if the tare weight of the skip is 600 kg? Note: Concrete weighs 2,400 kg per cubic metre. Answer to be provided in KILOGRAMS.
98. What is the weight of a 2 cubic metre concrete skip filled with concrete if the tare weight of the skip is 700 kg? Note: Concrete weighs 2,400 kg per cubic metre. Answer to be provided in KILOGRAMS.
99. What is the weight of a 50mm thick steel plate 5 metres long x 2 metres wide? Note: Structural steel weighs 7,840 kg per cubic metre. Answer to be provided in KILOGRAMS.
100. What is the weight of a 50mm thick steel plate 3 metres long x 3 metres wide? Note: Structural steel weighs 7,840 kg per cubic metre. Answer to be provided in KILOGRAMS.
101. What is the weight of a 25mm thick steel plate 5 metres long x 2 metres wide? Note: Structural steel weighs 7,840 kg per cubic metre. Answer to be provided in KILOGRAMS.
102. One metre of universal beam weighs 125 kg. One metre of scaffold plank weighs 7 kg. One square metre of mild steel plate weighs 156 kg. Find the total weight of a load made up of the following: 4 universal beams each 8 metres long; 15 scaffold planks each 4.4 metres long; 2 mild steel plates 4 metres long and 0.5 metres wide. Answer to be given in kg
SECTION F CRANE LOAD CHART
The load chart questions have been separated into sections pertaining to each specific crane class. Select the section that corresponds to the crane type you are assessing for.
Questions 103 to 114 apply only to Tower Cranes.
103. State three essential items of information you would expect to obtain from a load chart.
104. When dealing with a crane load chart, what is meant by the term "operating radius"?
105. List three items that need to be calculated to determine the crane capacity at radius?
106. If a heavy load is to be lifted, what precautions would you take to work within a given radius?
107. On the Load Chart, the hoist capacities for the winch in low speed is 12 tonnes and high speed, 6 tonnes. What precaution is necessary if changing from low to high speed?
108. On a crane Load Chart, define the terms GBS, MBS and GBL?
109. The crane you are operating has a single fall capacity of 7 tonnes, the load to be lifted is 10 tonnes. How can this lift be achieved using this crane?
110. On a level luffing Tower Crane, rigged with a 2-
111. The load indicator mechanism fails, could you still operate the crane?
112. The crane load chart is virtually unreadable from age or wear, could you still operate the crane and what action would you need to take?
113. How would you identify that the correct load chart is affixed to the crane?
114. On a Tower Crane, the load chart displays single fall maximum load 12 tonnes and double fall maximum load 16 tonnes. Why is the double fall capacity not twice the single fall capacity?
Questions 115 to 121 apply only to Derrick and Portal Cranes.
115. State three essential items of information you would expect to obtain from a load chart.
116. When dealing with a crane load chart, what is meant by the term "operating radius"?
117. List three items that need to be calculated to determine the crane capacity at radius?
118. If a heavy load is to be lifted what precautions would you take to work within a given radius?
119. The crane you are operating has a single fall capacity of 7 tonnes, the load to be lifted is 10 tonnes. How can this lift be achieved using this crane?
120. The crane load chart is virtually unreadable from age or wear, could you still operate the crane and what action would you need to take?
121. The Load Chart shows 30 tonnes at minimum and maximum radii. What is the reason for this constant capacity?
Questions 122 to 124 apply only to Bridge and Gantry Cranes.
122. Where would you locate the Safe Working Load (SWL) of a Bridge and Gantry Type Crane?
123. Bridge and Gantry type Cranes are sometimes fitted with a spreader attachment. If the spreader attachment is removed to allow lifting with a heavy lift hook, does the slings/lifting attachments weight (mass) have to be taken into consideration in the total weight (mass) to be lifted?
124. While operating a Bridge and Gantry Crane you observe the overload light glow on the instrument panel, what is your responsibility as an operator?
Questions 125 to 129 apply only to Vehicle Loading Cranes.
125. State three essential items of information you would expect to obtain from a load chart.
126. When dealing with a crane load chart, what is meant by the term "operating radius"?
127. List three items that need to be calculated to determine the crane capacity at radius?
128. If a heavy load is to be lifted what precautions would you take to work within a given radius?
129. The crane load chart is virtually unreadable from age or wear, and what action would you need to take?
Questions 130 to 145 apply only to Non-
130. State three essential items of information you would expect to obtain from a load chart.
131. When dealing with a crane load chart, what is meant by the term "operating radius"?
132. List three items that need to be calculated to determine the crane capacity at radius?
133. If a heavy load is to be lifted what precautions would you take to work within a given radius?
134. What do you understand when it is said that the load chart is based on 75% of tipping?
135. The load chart may have a heavy black line across the chart. What are the figures based on above the line and below the line?
136. Is a Truck Mounted mobile crane normally more stable when lifting over the rear or over the side?
137. How do you determine when to include the fall of the hoist rope as part of the rated load?
138. When the fly jib is offset at 15 degrees do you consider it could have a higher rated load than at 0 degrees offset?
.
139. When the precise reading is not available on a load chart, do you increase or decrease the load capacity?
140. When Travelling a load (Carry Deck) on level ground what is the margin of stability based. (Express as a percentage of tipping)?
141. If a crane has a fly jib stowed on the main boom section what may happen to the SWL of the crane?
142. How do you determine how the ratings are worked out on a fly jib?
143. Explain three uses of a range diagram?
144. How do you know if a hydraulic boom can be extended to lift a load?
145. How would you identify that the correct load chart is affixed to the crane?
All Rights Reserved L/W 2007
