SCHACKLES

1©Lifting Equipment Engineers Association 2013 – Unit 1.14 UNIT 1.14 - SHACKLES Contents Introduction 1. Manufacture 1.1 Body and pin forging 1.2 Heat treatment 1.3 Finish 2. Types of shackle 2.1 Bodies 2.2 Pins 3. Marking 4. Stress in shackles 5. Strength of shackles 6. Manufacturer’s tests 6.1 Type tests 6.2 Manufacturing tests and examination 7. The use of shackles 8. Examination 2 ©Lifting Equipment Engineers Association 2013 – Unit 1.14 Introduction Shackles are probably the most common and universal lifting accessory. Their uses are extensive. They may be used to connect a load directly to a lifting appliance, for the connection of slings to the load and/or lifting appliance, as the suspension for lifting appliances or as the head fitting in certain types of pulley blocks. The LEEA Code of Practice for the Safe Use of Lifting Equipment, Section 18, deals with shackles and students should refer to this as part of their studies. Although the old British Standards BS 3032, BS 3551 and BS 6994 have been withdrawn and/or declared obsolescent for several years, overseas manufacturers and their importing agents still make shackles generally to BS 3032 available. The current Harmonised European Standard for forged steel shackles for general lifting purposes is BS EN 13889:2003, which is a standard for Dee and Bow shackles grade 6. Shackles to the American US Federal Specification RR-C-271b are extremely popular and, in practice, it will be found that the vast majority of shackles in use today comply with its requirements. This is largely a result of the influence of the oil industry. It is very similar to the Harmonised European Standard and the shackles would meet this standard. This unit refers to the various standards in a general way, but to BS EN 13889 for specific detail, as the requirements for the tester and examiner are generally the same, irrespective of the standard to which the shackles were manufactured. As with eyebolts, it will not be long before an International Standard is issued, which will permit most of the shackles currently available within its manufacturing window. NOTE: Older shackles to US Federal Specifications call for greater care, as the design requirements may have varied greatly. In this case it is essential that the manufacturer’s specific advice is followed both for examination and for use. Current versions of Federal Specification RR-C-271b align to international requirements. However, older versions, prior to the mid 1980’s, were very different. Although you are unlikely to still find any in service it is worth noting a few matters. In many cases the marked SWL was based on the jaw of the shackle being filled, ie the load acting over the full width of the pin. The proof load may have been as low as SWL +10% with deformations as great as 10% allowed, provided the pin still fitted. As a result of the very different design criteria used in the older versions, and that some were marked in US (short) Tons, these shackles often appear to be stronger than similar sized shackles to other designs, when in fact they may well be weaker! The information in this unit does not therefore apply to such shackles. In the unlikely event you have to examine them, reference must always be made to the manufacturer’s original documentation and instructions. 3 ©Lifting Equipment Engineers Association 2013 – Unit 1.14 1. Manufacture 1.1 Body and Pin Forging Shackles are produced by forging. US Federal specification (and similar) shackles are usually drop forged, identifiable by the flash line around the body. Old British Standard shackles are bent from bar billets and therefore show no flash marks. In either case the body must be in a single piece and there should be no welding. Harmonised Standard BS EN 13889: 2003 allows for both methods, it states: Shackle bodies shall be forged hot in one piece. Excess metal from the forging operation shall be cleanly removed leaving the surface free from sharp edges. After heat treatment, furnace scale shall be removed. Profiling of blanks other than by bending and forging shall not be used. Shackle pins shall not be produced by a casting process. No welding shall be carried out on any part of the shackle body or pin. 1.2 Heat treatment After forging, but prior to machining and finishing, shackles are hardened and tempered. 1.3 Finish Shackles are supplied in various surface finishes, depending on the standard to which they are made. BS EN 13889 permits many of these, such as descaled, electroplated, hot dip galvanised or painted. 2. Types of shackle 2.1 Bodies There are two types of shackle body, the Bow and the Dee. See Figure 1. extrados intrados Dee Shackle Bow Shackle Figure 1 Types of Shackle Body 4 ©Lifting Equipment Engineers Association 2013 – Unit 1.14 Dee shackles are generally intended for joining two items in a straight line, whereas Bow shackles are designed to enable three or more items to be joined. As a result, Bow shackles are usually used when it is necessary to connect a number of slings to the hook of a lifting appliance. NOTE: Shackles generally to the old British Standards 3032 and 3551, were denoted by the diameter of the body. Other standards, including BS EN 13889, denote shackles by their working load limit. 2.2 Pins There are two types of shackle pin in common use, the screw pin, and the bolt, nut and cotter pin. See figure 2. Figure 2 Types of Shackle Pin Whilst BS EN 13889 specifies and gives relative dimensions of the above pins it also permits other suitable forms of pin head within the specification. Screwed pins with eye and collar are the most common type of pin and are suitable for a wide range of uses. However, if they are subject to movement and vibration (eg by a sling moving over the pin), they can loosen and unscrew. The bolt with hexagon head, hexagon nut and split cotter pin is used where a positive connection is required as it cannot unscrew unintentionally. They are also ideal where a permanent connection is required, (eg connecting the top slings to a spreader beam). 3. Marking BS EN 13889 requires that each shackle is legibly and indelibly marked by the manufacturer with the following information, in a way that will not damage the mechanical properties of the shackle: a. Working Load Limit in tonnes. b. Grade mark. c. Manufacturer’s name, symbol or code. d. Traceability code. It also requires that pins of less than 13mm diameter are marked with either the grade mark or the traceability code and pins 13mm diameter or above are marked with the grade mark, traceability code and manufacturer’s symbol. 5 ©Lifting Equipment Engineers Association 2013 – Unit 1.14 Although the standard does not specify where the marking should be made, in order to meet the requirement not to impair the mechanical properties of the shackle, this must be in a low stress part (eg the straight portion of the standing leg), and not around the crown. 4. Stress in shackles A shackle is carefully designed so that the strength of the body and pin are approximately equal. In order to achieve this, the pin will be of a larger diameter than the body. The pin acts as a beam. If it is subject to a point load, it will be both in a condition of bending and of double shear. If the jaw is fully filled, so that the load is spread evenly over the full width of the pin, it will only be in double shear. A shackle pin is at its strongest when in a condition of double shear. For a point load, the maximum tensile stress occurs at the centre on the outward facing side of the pin. Standards assume that the pin will be subject to a point load, as this is worst condition, when calculating the pin diameter. 5. Strength of shackles The strength of a shackle depends on five factors: 1. The material from which it is made and its heat treatment. 2. The diameter of the material of the shackle. The larger the diameter of the shackle body the stronger it will be for a given inside width. 3. The diameter of the material of the pin. Similarly, for a given width in the jaw of the shackle, the larger the diameter of the pin, the stronger the pin will be. 4. The width of the jaw. For a given size of shackle material, the wider the jaw and the greater the diameter inside the bow, the weaker the shackle will be. 5. The inside diameter of the bow where this differs from the width of the jaw. 6. Manufacturer’s tests 6.1 Manufacturing tests and examination The manufacturing tests required by BS EN 13889 are different depending on the quality management system operated by the manufacturing company. 6.1.1 Manufacturers with an accredited EN ISO 9001 certification If the manufacturer has a quality system conforming to EN ISO 9001 certified by a certification body accredited to EN 45012 the following tests and examinations must be made: 6 ©Lifting Equipment Engineers Association 2013 – Unit 1.14 Proof load test If the production batch is between 1 and 3000 off, they must proof load test 3% of the batch. This decreases to 2% for batches of 3001 to 5000 and to 1% for batches of more than 5000. A manufacturer may elect to operate an alternative test regime of 2% of all his production, irrespective of the size of the batches. The proof load applied is twice the WLL no permanent deformation is allowed following the manufacturer’s proof load. Non-destructive test After heat treatment and descaling all bodies and pins must be subjected to magnetic particle or dye penetrant examination. Visual examination All shackles must be visually examined. The examination can be carried out on the completed shackles or in stages during the production provided that all relevant features are examined. 6.1.2 Manufacturers without an accredited EN ISO 9001 certification If the manufacturer does not have a quality system conforming to EN ISO 9001 certified by a certification body accredited to EN 45012 the following tests and examinations must be made: Proof load test All of the production batch must be proof load tested to twice the WLL no permanent deformation is allowed following the manufacturer’s proof load. Static test and Charpy impact test One sample per production batch must be subjected to a static test and three samples must be subjected to a Charpy impact test. Non-destructive test After heat treatment and descaling all bodies and pins must be subjected to magnetic particle or dye penetrant examination. Visual examination All shackles must be visually examined. The examination can be carried out on the completed shackle or in stages during the production provided that all relevant features are examined. 7. The use of shackles Before considering the matters that must be taken into account during an examination, it is important to look at the use of shackles and the defects and damage that can occur due to misuse. Full details of the safe use of shackles are given in Section 18 of the LEEA Code of Practice for the Safe Use of Lifting Equipment, which should also be studied. 7 ©Lifting Equipment Engineers Association 2013 – Unit 1.14 The correct shackle body and pin must be used and they must be of the same grade. Accidents have occurred where the user has put a mild steel pin in an alloy steel body or replaced a screw pin with a nut and bolt. The shackle must be compatible with all of the other fittings in the slinging arrangement, taking account of increased resultant loads due to angular loading, and it must seat correctly with mating parts. If the shackle jaw is too small it will be forced open and/or bent and if it is too wide the shackle may twist under load and take on a permanent set. Shackles should be loaded along the axial plane of the body sides or the body, and possibly the pin, will be bent. See Figure 3. Figure 3 The pin must be correctly screwed into the shackle eye, finger tight and locked using a small tommy bar, so that the collar of the pin is fully seated on the shackle eye. The pin must be the correct length so that it penetrates the full depth of the screwed eye and allows the collar of the pin to bed on the surface of the drilled eye with only 1 or 1½ turns of thread remaining exposed in the jaw. Where shackles are fitted with a bolt and pinned nut, the length of the plain portion of the bolt should be such that the nut will jam on the inner end of the thread and not on the eyes of the shackle, thus leaving the bolt free to rotate. If these steps are not taken there is every chance that the body of the shackle will be closed in and permanently deformed when the pin is tightened. Shackles which have a positively locked pin (eg bolt, nut and split cotter pin), should be used for applications where the shackle cannot be observed or where the pin may unscrew when in service and, in the worst case, release the load. The pin will become scored and gouged if it has been unscrewing, even by a small amount, under load. This will lead to stress raisers. Eccentric loading will cause the shackle to twist so that the load comes onto the angle formed by the body and pin (see Figure 4). This can twist the body, open the jaw and bend the pin. 8 ©Lifting Equipment Engineers Association 2013 – Unit 1.14 Figure 4 8. Examination Shackles fall under the heading of ‘lifting accessories’ in modern legislation and therefore should be examined by a competent person at periods not exceeding six months. Nothing will be achieved by a load test during the examination of in-service shackles as the strength is known prior to the examination. Indeed, such a test can be damaging if the item is worn but within acceptable limits. In-service shackles should therefore be carefully visually examined. In particular the following should be checked: 1. Free working of the pin. 2. Threads: The threads, both male and female, should be fully formed with no flats or worn portions and must be full size. There should be no excessive play when the pin is screwed in by hand from either the correct or reverse side. 3. Holes must align. The pin hole should not be too large so as to allow a gap when the pin is in place. 4. The maximum permissible wear is 8% reduction in material diameter on either the pin or the body. 5. There should be no signs of nicks, cracks, corrosion or chemical attack. 6. There should be no distortion. The body should have a good shape and the pin must show no signs of bending. 7. The length of pin and thread length should be correct for the shackle body. In the case of bolt and nut pins, when fully tightened they should not deform the body. In the case of screwed pins the thread must not be too long so that continued tightening results in closing the jaw gap of the body or so that more than the tapered run out of the thread is exposed inside the jaw of the shackle. Neither must they be too short so that the collar or seat of the pin is held away from the body when the pin is fully tightened. 8) Marking should be clear and legible.