— y Watson MEMO As from March 1° 2011, all Lifting Brackets, Lifting beams and Lifting Lugs will be stamped up / marked up with a WSS Number (currently LB). This will be done following either; 1. Testing and MPI 2. Issue of Design check certificate and MPI THIS DOES NOT AFFECT THE LB/LL NUMBERS ISSUED BY THE DESIGN DEPARTMENT. This new procedure is simply to clarify that these pieces of equipment have been tested by the maintenance department. These numbers can only be issued by Bill Bowden or Malcolm Tyrer. Design department will carry on with their existing numbering system. Regards Simon Atherton - H&S Manager Bill Bowden — Works Engineer Watson Steel Structures Ltd PO Box9, Lostock Lane, Lostock, Bolton, Lancs, BLS <1 x ‘Tel: +44 01204 699999 Fax +44 01204 694543 &> eee te eeneenet atl a1 Bose tect indo 3 y, A subsidary of Severfield Rowen Plc 7 [esa]Procedure for _the Referencin; Identification _of_lifting Brackets on Fabrication Drawings. Background A safety and practicality issue has been raised highlighting a difficulty identifying the correct lifting brackets and bolts for a piece being lifted. This difficulty is equally present in the factory, at the painters and on site, To overcome this problem and with immediate effect the following procedure must be adopted on all projects. ‘This document should be read in conjunction with the WSSL ‘Procedure for the design of Lifting Beams and Lifting Lugs’. Procedure This procedure must be communicated to the project drawing office as it is thelr responsibility to ensure that the fabrication drawings are appropriately edited. «Each fabrication/assembly drawing must identify the lifting bracket references for lifting the plece/assembly on that drawing. This also includes standard lifting brackets. 4 Aseparate text box must be located on the fabrication/assembly drawing listing each of the bracket references associated with that piece/assembly. ‘When more than one type of lug is to be used, the location of each lug type must be Identified on the drawing of the piece/assembly. ‘© Fabrication drawings of the lifting brackets must clearly identify the following: ‘© Bolt sizes and grades to be used. © The Safe Working Load, The Test Load and the Design Load as identified on the calculation sheets, © The calculation reference number. ‘* IFrequired, separate drawings must be produced to clearly show the lifting arrangements for each lifting condition ie, workshop, painters, site. Considerations ‘The contract teams along with the project drawing office must consider the number of sets of lifting brackets that will be required. Consideration must be given to how each piece will be lifted throughout the delivery process from shop to painters to For example the following should be considered: ‘+ How many sets of brackets are required? © Dependant on number of similar assemblies © Expected re-use of brackets ©. Separate brackets at Lostock, sub-let fabricators, painters and site? ‘© Numbers of sets of bolts required to service the above. Can the bolts be re-used? © The lifting arrangement may be different in the shop/painters than at site. E.g. A tandem lift may be required at the painters as opposed to a single crane lift on site. This is particularlyrelevant ifthe piece weighs more than 30te but may also be an issue for lighter pieces with awkward geometry. Does the piece need to be turned at site or the painters? Separate bolts need not be ordered for testing purposes.PR FOR THE DESIGN OF LIFTING BEAMS AND LIFTING Lt With immediate effect, the following procedure must be followed when designing lifting lugs and lifting beams. ‘The following Flow-Diagrams should be followed, placing emphasis on the flow of information with the Erection Department and Works Engineer, Design drawings / sketches are to show welded attachments and details in accordance ‘with the attached sketch “Typical Arrangement of a Lifting Beam”. STORAGE OF CALCULATIONS / DETAILS ‘When commencing the design of a Lifting Beam or Lug, the next reference number shall be taken from the register stored in the Design directory under the folder “Lifting Beams and Lugs”, The reference shall be used to name the element and slso for the calculation numbering. For example a lifting beam may be referenced LB O01, and the cales numbered 1B/001/01..02 etc. All completed calculations, details, check certificates are to be scanned and stored in the Design Directory in the folder “Lifting Beams and Lugs”. The file name must he the same as the reference, ie LBOO! will be saved as file name LBOOI. SAFE WORKING LOAD (SWL) ‘The load to be lifted shall be less than the SWL. ‘SWL!s shall be rounded up to the nearest 5 Tonnes for loads upto 20 Tonnes and to the. nearest 10 Tonnes thereafter. SWL's are to be at least 10% greater than the calculated lift weight. ‘Tho self weight of a lifting beam must not be included in the SWL but must be added to. it when designing the beam, ‘A SWL must be calculated for each individual piece of lifting equipment within a lifting scheme. For example: A beam lifted using 45 degree strops connected to separate lifting lugs. In this case the actual load on cach lug should be calculated and then an appropriate SWL for each lug determined. ‘TEST LOAD ‘The TEST LOAD shall be calculated using the following formula, For SWI < 10Te ‘TEST LOAD = 2x SWL For SWL > 10Te ‘TEST LOAD = (1.04 x SWL) + 9.6 TeFor SWE > 160Te ‘TEST LOAD = 1.1 x SWL Note: The designer must consider the likelyhood of significant impact loading during the lift, and iPnecessary increase the test load accordingly. DESIGN LOAD ‘The Design Load is the factored Test Load. ‘Therefore, DESIGN LOAD = 1.4x TESTLOAD ALL DESIGNS SHALL HAVE A SEPARATE SKETCH INDICATING HOW ‘THE LOAD IS TO BE APPLIED AND LISTING THE SWL (Io), THE TEST LOAD (Te) AND THE DESIGN LOAD (KN). EGI: A beam weighing 35 tonnes is to be lifted using bolted lugs connected to strops at 45 degrees arranged symetrically about the lift centre of gravity. Gravity load per lug = 17.5 te. Strop load =17.5te x 1.414 = 24.7 to ‘Min SWL per lug = 24.7 4+ 10% = 27.20 Roundup to 30 Tonnes ‘Test Load = (30 x 1,04) + 9.6 = 40.8 Tonnes, say 41 Tonnes Design Load = (41 x 10) x 1.4=874KN Consider Impact to be an issue, allow 25% impact factor. Load during Lift = 24.7 Tonnes x 1.1 x 1.25 = 34.0 Tonnes < Test Load, 41 Tonnes, OK EG2: Consider a lifting beam to be designed to lift a 35te heam. 2 vertical strops between the plece and the ends of the lifting beam with 2no 45 degree strops to the erane hook connected to the beam with welded lugs. Lifting Beam SWL = 35 te +10% =38.5 te, Min SWL=40 te Test Load = (40 x 1.04) +9. 51.2 te say 52 Tonnes Design Load = (52 x 10) x 1.4 = 728KN (+ Lifting Beam SW) Design Load per Lug = 728 / 2x 1.414 = SISKN (+ Proportion of Lifting Beam SW) Iain Hill 16 November 2010ber "e318 Dale Process Owner ‘Aurea by Wes. a 20.03.2013 ‘Contact Manager ‘Quality Assurance Work instruction 7.0 Drawing Notes FET ER itd Drawings are to contain standardised notes to ensure consistency of lifting lug design see examples of note boxes and sketches below: Example 1 Swe XX Te (6.9, Verlical) TEST XX Te (e.g. Vertical) LIFT ANGLE Xx? DESIGNLOAD __=_XX Te (0.9, Vartical) Example 2 WHERE LIFTING POINT HOLE IS FORMED BY THERMAL CUTTING HARDENED SURFACE IS TO BE REMOVED BY REAMING OR BORING Exemple 3 WELD INSPECTION 1) ISO 5817 LEVEL B ACCEPTANCE CRITERIA 2) ALL WELDS TO BE 100% EXAMINED (FW=VISUAL & MPI, FPBW / PPBW = VISUAL, MPL& UT) 3) WELD SIZES TO BE VERIFIED USING A TWI TYPE WELD GAUGE Example _4 ENSURE LUG BASE PLATE IS EXTENDED TO ENABLE FW TO BE RETURNED INTERNAL DOCUMENT UNCONTROLLED WHEN PRINTED Page 6 of 8WATSON STEEL STRUCTURES LTD Ra DESIGN CHECK CERTIFICATE LIFTING EQUIPMENT ITEM REFERENCE: LB1001 SWL: 25 Tonnes DESCRIPTION: 12m Span Lifting Beam, 323 x 10 CHS Gr $355 CALCULATIONS / LB/ 1001 /1-8 DRAWINGS: DESIGN CODES/ —_/ WSSL Procedure for the design of lifting beams and STANDARDS: lugs. BS5950-1: 2000 The above noted calculations / drawings have been produced and verified to be correct in accordance with the aforementioned design codes and standards Design by: On behalf of: Signature: Date: Design Check by: On behalf of: Signature: Date: Joe Designer Watson Steel Structures Ltd Joe Designers Mate ‘Watson Steel Structures LtdFLOW CHART FOR THE DESIGN OF LIFTING LUGS REQUIREMENT FOR LIFTING IDENTIFIED. Lua) DESIGNER TO REVIEW LIBRARY FOR EXISTING SUITABLE DESIGN ves SUITABLE DESIGN AVAILABLE? LO (CARRY OUTNEW DESION USE DESIGN SN CHECK BY PUT DESIGN ‘CENG INTOLIBRARY ISSUE TO WORKS ENGINEER CAN THE LUG BE TESTED DESIGN TO PRODUCE, DESIGN CERTIFICATE NDT ALL WELDS: ISSUE TO CONTRACT TEAM DETAIL & FABRICATE LOAD TEST IDENTIFY SWLON Lue peer ocr "WORKS ENGINEER TO PRODUCE, CERTIFICATION PACKAGE IsSUB-TO WORKS ENGINEER /K— FULL COPY ISSUED ————|_ ronsonELOW CHART FOR THE PRODUCTION OF LIFTING BEAMS IDENTIFIED REQUIREMENT FOR LIFTING BEAM DESIGNER TO REVIEW LIBRARY FOR EXISTING SUITABLE DESIGN ves SUITABLE DESIGN AVAILABLE? xo ‘CARRY OUT NEW DESION USE DESIGN| 1 DESIGN CHECK BY PUT DESIGN CENG INTO LIBRARY ISSUE TO ERECTION commie MODIFY MANAGER FOR COMMENT. DESIGN COMMENT ISSUE TO ISSUE TO WORKS CONTRACT TEAM, ENGINEER DETAIL & CAN THE BEAM FABRICATE, BE TESTED DESIGN To PRODUCE. DESIGN CERTIFICATE LOAD TEST NDT ALL WELDS ‘THE BEAM IDENTIFY SWLON ISSUE TO WORKS ENGINEER BEAM RI ‘WORKS ENGINEER TO FULL COPY ISSUED CERTIFICATION TODESIGN PACKAGE