Modulift MOD 24 - User Manual

User Instructions
Modulift UK Ltd tel: +44(0)1202 621511 email: sales@modulift.com www.modulift.com
The Modulift Spreader is modular in length, and every spreader consists of 1 pair of End Units and
Drop Links, with intermediate struts that can be bolted into the assembly to achieve dierent spans.
 Personnel using this system should be suitably trained, competent and have a clear
understanding of Safe Slinging procedures.
 The use of Modulift equipment must be in accordance with the procedures laid down in
‘Lifting Operations and Lifting Equipment Regulations 1998’ (LOLER).
 Never exceed stated WLL – Adhere to WLL in Table 2 for particular sling angle used.
 The top sling length is critical to the safe use of the spreader – Adhere to Table 2.
 Ensure Drop Links hang down, and smaller shackles are connected to bottom hole of Drop Link.
 Do not under any circumstances hang load(s) from the tube or anges – the spreader is designed for
axial compression, not bending.
WARNING!
MOD 24
MOD 24 has an assembled span ranging from 1 metre to 8 metres in 0.5 metre increments.
MOD 24 Beam Specication
 Rated at 24 tonnes WLL at 5 metres span
(30° STV). See Load Table for WLL at longer spans.
 ‘Sling to Vertical’ angle, β, 45 degrees or less.
 End Units & Drop Links are rated at 12 tonnes WLL each (24 tonnes combined capacity).
 Bolt tightening torque: 150Nm. Spanner size required: 30mm.
 Recommended additional equipment: Torque Wrench, Podger Spanner and Ring Spanner.
P1 P2P3–P5
Span
β
P6
P7 P8
β = Sling to vertical angle
Strut
Drop link
End unit sub-assy
Larger shackle
Smaller shackle
Drop link
Table 1 – Component List
Part Ref. Description Weight/item
P1 End Unit 17kg
P2 Drop Link 5kg
P3 2.0m Strut 41kg
P4 1.0m Strut 24kg
P5 0.5m Strut 16kg
P6 17t Shackle 8kg
P7 12t Shackle 5kg
P8
M20 x 50, Grade 8.8 HT Bolts, Nuts & Washers
Fig. 1 – Typical Spreader Assembly

Summary

MOD 24 Beam Specification

Assembly Procedure

Dos & Donts

Manufacturers Contact Details

Introduction

EC declaration of conformity

Markings

Intended use

Assembly

User instructions

Lifting: Planning and Operations

Inspection prior to each use

General instructions for safe use

Thorough examination

Repair

End of life

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

The Modulift Spreader is a modular lifting accessory designed for use in lifting operations, functioning as a spreader beam to distribute loads and prevent crushing. It is constructed from structural mild steel and is intended for axial compression, not bending. The system is modular, allowing for various assembled spans by combining End Units, Drop Links, and intermediate Struts. The MOD 24 model, for instance, can achieve assembled spans ranging from 1 meter to 8 meters in 0.5-meter increments.

Function Description:

The primary function of the Modulift Spreader is to provide a stable and controlled lifting point for loads, particularly those that are wide or require multiple attachment points to prevent deformation or damage during lifting. By using a spreader beam, the top slings are kept at a specific angle (sling to vertical angle, or STV), which reduces the horizontal forces on the load and ensures that the lifting force is primarily vertical. This is crucial for maintaining the integrity of the load and the safety of the lifting operation. The modular design allows the spreader to be configured to suit different load widths and lifting requirements, making it a versatile tool for various lifting scenarios. The spreader is designed to be loaded through its drop links, ensuring that the forces are correctly transmitted through the beam in axial compression.

Usage Features:

The Modulift Spreader is designed for ease of assembly and configuration, though it requires careful adherence to instructions and safety procedures.

• Modular Assembly: The system comprises End Units, Drop Links, and various lengths of Struts (e.5m, 1.0m, 2.0m). These components are bolted together to achieve the desired span. The assembly process involves laying out components, checking flanges for debris, bolting them together with specified torque, and attaching drop links and shackles.
• Configurability: The ability to combine different strut lengths allows for precise adjustment of the spreader's span to match the load's dimensions. This flexibility is a key advantage, as it eliminates the need for multiple fixed-length spreader beams.
• Sling Angle Management: The design emphasizes maintaining a specific "Sling to Vertical" angle (β), typically 45 degrees or less, for the top slings. This angle is critical for the safe use of the spreader, as it directly impacts the forces within the beam and the stability of the lift. The manual provides guidance on minimum top sling lengths for different STV angles to ensure safe operation.
• Load Attachment: Loads are attached to the lower holes of the drop links using lower slings and shackles. It is explicitly stated that loads must not be hung from the spreader tube or flanges, as the beam is designed for axial compression, not bending.
• Safety Critical Components: Bolts, nuts, and washers are provided and must be tightened to a specified torque (e.g., 150Nm for MOD 24) using appropriate tools (torque wrench, podger spanner, ring spanner). The number and grade of bolts are critical for safe use, especially at longer spans.
• Clearance Requirements: Riggers must ensure adequate clearance between the sling end fitting and the end unit to prevent interference during lifting.
• Stability Considerations: The stability of the lifting rig is paramount. The center of gravity (CoG) of the load must be below the connection points of the spreader to ensure a stable lift. If the CoG is above the connection points, the rig becomes unstable and could lead to toppling. The rig must also be designed so that the CoG of the item being lifted is directly below the hook point to prevent tilting and overloading of lifting equipment.
• Trained Personnel: All personnel involved in using the system must be suitably trained, competent, and have a clear understanding of safe slinging procedures. Lifting operations must be planned by a competent person, including risk assessment, method statements, force calculations, and CoG determination.
• Compliance: The use of Modulift equipment must comply with relevant regulations, such as 'Lifting Operations and Lifting Equipment Regulations 1998' (LOLER) and the EC Machinery Directive 2006/42/EC.

Maintenance Features:

Proper maintenance and inspection are vital for the continued safe operation of Modulift products.

• Pre-Use Inspection: Before each use, the Modulift product(s) must be inspected for obvious damage or deterioration. This inspection should be conducted in accordance with local regulations. Any doubt regarding the product's condition means it must not be used for a lifting operation.
• Thorough Examination: A thorough examination by a competent person is required at intervals not exceeding six months, or sooner if the equipment is used in extreme environments or local laws dictate.
• Component Integrity: Components with cracks, visible distortion, twisting, severe corrosion, or gouges exceeding 10% of the material thickness must be discarded and replaced or repaired. Fasteners (bolts, nuts, washers) should also be inspected prior to each use and discarded if any visible damage to the shank or thread is found.
• Repair Procedures: Repairs must ideally be carried out by Modulift. In exceptional circumstances, repairs by a third party are permitted only with Modulift's express approval and strict adherence to their requirements. Failure to contact Modulift before repairs can invalidate the product's declaration.
• Disposal: Modulift products, being made from structural mild steel, can be widely recycled at the end of their service life.
• Documentation: The manufacturer's EC Declarations of Conformity certificate must be in order for all equipment, and the Modulift product(s) must be precisely as ordered. User instructions and GA drawings provide detailed technical data and intended use.
• Temperature Rating: Modulift main generic products are rated for use between -20°C and 60°C. Custom products may have different ratings, which would be stated on their certificate.
• Fatigue Consideration: Prolonged exposure to variable loads can induce fatigue failure, even if the Working Load Limit (WLL) has not been exceeded. This risk should be considered when determining service intervals.
• Hazardous Conditions: In exceptionally hazardous conditions (e.g., offshore activities, lifting persons, dangerous loads like molten metals or corrosive materials), the degree of hazard must be assessed by a competent person, and the WLL adjusted accordingly.

Modulift MOD 24 Specifications

General

Maximum Load Capacity/WLL/SWL	24 tonnes
Material	High-Grade Steel
Color	Yellow
Span Length	Variable, depending on configuration
Application	Lifting and rigging operations
Length	Variable, depending on configuration
Design Standard	EN 13155