Lifting and Rigging Safety

Lifting and Rigging Safety

Lifting and rigging operations are among the highest-risk activities on construction sites, oil and gas projects, refineries, power plants, manufacturing facilities, and shutdown projects. A single mistake during lifting can result in dropped loads, equipment damage, serious injuries, or fatalities.

Safe lifting is not simply about attaching a sling to a load and operating a crane. It requires proper planning, competent personnel, suitable lifting equipment, effective communication, and continuous control of hazards throughout the operation.

A successful lifting operation begins before the crane starts moving. The load, lifting equipment, ground conditions, weather, lifting route, personnel, and surrounding hazards must all be considered.

Why Lifting and Rigging Safety Is Important

A suspended load contains significant potential energy. If a sling fails, a shackle becomes disconnected, the load shifts, or the crane becomes unstable, the consequences can be severe.

Common lifting incidents include:

• Dropped loads
• Sling failure
• Crane overturning
• Load swinging
• Workers being struck by loads
• Hands being trapped between loads
• Contact with overhead power lines
• Failure of lifting accessories
• Crane collision with structures
• Uncontrolled movement of materials

Many of these incidents are preventable when lifting operations are properly planned and controlled.

Understanding the Difference Between Lifting and Rigging

Lifting and rigging are closely connected, but they are not exactly the same.

What Is Lifting?

Lifting is the process of raising, lowering, or moving a load using equipment such as cranes, hoists, forklifts, or other mechanical lifting devices.

The lifting equipment provides the force required to move the load.

What Is Rigging?

Rigging involves selecting and attaching lifting accessories to safely connect the load to the lifting equipment.

Rigging equipment can include:

• Wire rope slings
• Webbing slings
• Chain slings
• Shackles
• Hooks
• Eye bolts
• Spreader beams
• Lifting beams
• Clamps
• Master links

The rigging arrangement must be suitable for the load, lifting method, and environmental conditions.

Proper Lifting Planning

Good lifting operations begin with planning. The level of planning should reflect the complexity and risk of the lift.

Determine the Load Weight

The actual weight of the load should be known before lifting whenever reasonably practicable.

Do not rely on assumptions or visual estimates.

The load weight may be obtained from:

• Manufacturer information
• Equipment drawings
• Shipping documents
• Load data plates
• Engineering calculations
• Weighing records

If the load weight is uncertain, the lifting team should resolve the uncertainty before proceeding.

Identify the Load’s Center of Gravity

The center of gravity determines how the load will behave when it is lifted.

If the center of gravity is not properly considered, the load may tilt, rotate, or shift unexpectedly.

The lifting points and sling arrangement should therefore be selected according to the load’s center of gravity.

Plan the Lifting Route

The lifting path should be examined before the operation begins.

The team should consider:

• Buildings and structures
• Scaffolding
• Equipment
• Pipelines
• Electrical lines
• Other cranes
• Vehicles
• Personnel
• Excavations
• Restricted areas

The objective is to ensure that the load can travel safely from the lifting point to the final position.

Selecting the Correct Lifting Equipment

Every lifting accessory has a specific capacity and application. Selecting equipment simply because it is available is unsafe.

Check the Working Load Limit

The Working Load Limit, commonly referred to as WLL, must be suitable for the intended lifting arrangement.

The lifting team should consider the load weight and the configuration of the rigging system.

The capacity of the complete lifting arrangement is limited by its weakest suitable component.

Inspect Slings Before Use

Slings should be inspected before use for signs of damage or deterioration.

Look for:

• Cuts
• Abrasion
• Broken wires
• Kinks
• Corrosion
• Heat damage
• Chemical damage
• Distorted fittings
• Damaged identification tags

A damaged sling should be removed from service and handled according to the site’s inspection and disposal procedure.

Inspect Shackles

Shackles should be checked for deformation, cracks, excessive wear, corrosion, and damaged pins.

The shackle should be suitable for the intended load and connection.

Never replace a proper shackle pin with an improvised bolt or other unsuitable component.

Inspect Crane Hooks

Crane hooks should be inspected for visible damage, deformation, excessive wear, cracks, and problems with the safety latch where fitted.

The hook should be correctly positioned so that the load is not applied in an unsafe manner.

Understanding Sling Angles

Sling angle has a major effect on the forces experienced by the sling legs.

Why Sling Angle Matters

As the angle between the sling legs becomes smaller relative to the horizontal, the tension in each sling leg increases.

This means that a sling arrangement may experience significantly greater forces than the actual weight of the load.

For this reason, riggers should never assume that a multi-leg sling automatically provides a simple equal sharing of the load.

Avoid Excessive Sling Angles

The lifting plan should specify suitable sling configurations and angles where required.

The manufacturer’s instructions, applicable standards, and site lifting procedures should be followed when determining safe configurations.

Competent and Trained Personnel

Lifting operations require people with appropriate knowledge, training, experience, and authorization.

Responsibilities of the Rigger

A competent rigger should understand:

• Sling selection
• Load weight
• Center of gravity
• Sling angles
• Connection methods
• Load stability
• Inspection requirements
• Communication signals
• Exclusion zones

The rigger must ensure that the load is properly connected before it is lifted.

Responsibilities of the Banksman or Signalman

The signalman provides clear communication between the lifting team and crane operator when required by the lifting arrangement.

They should understand the approved hand signals or communication system being used.

Only authorized personnel should give lifting signals when the site’s procedure requires a designated signalman.

Responsibilities of the Crane Operator

The crane operator must operate the equipment within its rated capacity and follow the approved lifting plan and site procedures.

The operator should never proceed with a lift when the signal or instruction is unclear.

Crane Capacity and Load Charts

A crane’s maximum rated capacity is not necessarily available in every lifting condition.

Understand Radius

Crane capacity can change significantly depending on the operating radius.

As the load moves farther from the crane, the available lifting capacity may decrease.

The crane operator and lifting team must therefore refer to the correct load chart for the actual configuration and operating conditions.

Consider Crane Configuration

Factors that can affect crane capacity include:

• Boom length
• Boom angle
• Operating radius
• Counterweight configuration
• Outrigger position
• Crane configuration
• Ground conditions
• Lifting accessories
• Wind conditions

The planned lift should remain within the manufacturer’s specified limits.

Ground Conditions and Crane Stability

Crane stability depends heavily on the supporting surface.

Check the Ground

Before positioning a crane, the lifting team should evaluate the ground conditions.

Particular attention should be given to:

• Soft ground
• Uncompacted soil
• Underground voids
• Excavations
• Trenches
• Drainage channels
• Underground services
• Slopes

The crane should be positioned according to the approved lifting plan and manufacturer’s requirements.

Use Suitable Outrigger Support

Where outriggers are required, suitable support arrangements should be provided according to the crane manufacturer’s requirements and site procedures.

Improper support can contribute to instability or overturning.

Exclusion Zones During Lifting

One of the most important lifting controls is keeping people away from suspended loads.

Never Stand Under a Suspended Load

Workers should never position themselves beneath a suspended load unless a specifically engineered and authorized procedure permits otherwise.

A load can fall or move unexpectedly even when the lifting operation initially appears stable.

Establish a Barricaded Area

An appropriate exclusion zone should be established around the lifting operation.

Barricading should consider:

• Load path
• Swing radius
• Possible load movement
• Crane movement
• Falling-object potential
• Nearby work activities

Unauthorized personnel should not enter the controlled area.

Communication During Lifting Operations

Communication failures are a common contributor to lifting incidents.

Use Clear Signals

The crane operator and signalman should agree on the communication method before starting the lift.

Depending on the operation, communication may involve:

• Standard hand signals
• Radio communication
• Direct verbal communication
• Dedicated lifting communication systems

The method should be appropriate for the visibility, distance, noise level, and complexity of the lift.

Stop When Communication Is Lost

If the crane operator cannot understand the signal or loses communication with the designated signalman, the operation should be stopped safely.

Guessing what another person means during a lifting operation can have serious consequences.

Tag Lines and Load Control

Tag lines can help control the movement and rotation of suitable loads.

Use Tag Lines Correctly

A tag line should be attached and positioned so that workers can control the load from a safe location.

Workers should never wrap a tag line around their hands or body.

Avoid Hands Near Pinch Points

Workers should maintain safe hand positions when guiding loads.

Hands and fingers can easily become trapped between a load and another object during final positioning.

Weather Conditions

Weather can significantly affect lifting operations.

Wind Can Affect Suspended Loads

Large or lightweight loads can behave like sails in strong winds.

Wind may cause:

• Load swinging
• Load rotation
• Loss of control
• Increased crane loading
• Difficulty positioning the load

Lifting should be carried out within the manufacturer’s and site’s specified environmental limits.

Visibility Matters

Poor visibility caused by darkness, dust, fog, rain, or other conditions can affect communication and load control.

Additional controls or suspension of the operation may be necessary when visibility becomes inadequate.

Common Lifting and Rigging Mistakes

Many lifting incidents result from basic failures rather than complicated technical problems.

Using Damaged Lifting Accessories

Damaged slings, shackles, hooks, or other accessories should never be used simply because the lifting operation is considered small.

A small load can still cause a serious incident if the lifting accessory fails.

Exceeding Rated Capacity

Never exceed the rated capacity of the crane or lifting accessory.

The capacity must be considered for the actual configuration and lifting arrangement.

Poor Rigging Arrangement

Incorrect sling positioning can make a stable load unstable.

The rigging arrangement should prevent unintended slipping, shifting, or rotation.

Standing in the Line of Fire

Workers sometimes stand too close to loads because they want to guide them quickly.

This exposes them to crushing, striking, and pinch-point hazards.

Rushing the Operation

Production pressure should never be used as a reason to skip inspection, planning, communication, or exclusion-zone controls.

A few minutes saved during preparation can never justify the potential consequences of an uncontrolled lift.

Lifting Equipment Inspection and Certification

Lifting equipment should be inspected and maintained according to applicable requirements, manufacturer instructions, and the site’s inspection system.

Pre-Use Inspection

Users should conduct the required pre-use checks before using lifting equipment.

The inspection should identify visible defects and conditions that could affect safe operation.

Periodic Inspection

Lifting equipment and accessories should undergo periodic examination by appropriately competent personnel at the required intervals.

Records should be maintained according to the organization’s lifting equipment management system.

Lift Plan and Method Statement

Complex or high-risk lifting operations require detailed planning.

What a Lift Plan May Include

Depending on the operation, a lift plan may address:

• Load description
• Load weight
• Crane selection
• Crane configuration
• Lifting radius
• Boom configuration
• Rigging arrangement
• Ground conditions
• Lifting route
• Exclusion zone
• Communication method
• Weather limitations
• Personnel responsibilities
• Emergency arrangements

The level of detail should reflect the complexity and risk of the lift.

Toolbox Talk Before Lifting

A toolbox talk gives the lifting team an opportunity to discuss the planned activity before work starts.

Important Points to Discuss

The team should understand:

• What is being lifted
• Where the load will be moved
• Who is responsible for signaling
• What rigging equipment will be used
• Where workers must stand
• What the exclusion zone is
• What communication method will be used
• What conditions require the lift to stop

Everyone involved should understand their responsibilities before the crane begins the lift.

Safe Lifting Sequence

A controlled lifting sequence helps the team identify problems before the load is fully raised.

Perform a Trial Lift

Where appropriate, the load can be raised slightly from its initial position to confirm that the rigging arrangement is stable and the load behaves as expected.

The team can then check for:

• Load balance
• Sling positioning
• Unexpected movement
• Rigging security
• Crane stability

If something does not look correct, the load should be safely lowered and the problem corrected.

Move the Load Slowly

Sudden crane movements can cause the load to swing or shock-load the rigging system.

Smooth and controlled movements are essential throughout the lifting operation.

Emergency Preparedness

The lifting team should know what to do if something goes wrong.

Possible Emergency Situations

Emergency scenarios may include:

• Sling failure
• Crane malfunction
• Load instability
• Loss of communication
• Sudden weather deterioration
• Contact with an obstruction
• Personnel entering the exclusion zone

The response should follow the site’s emergency and lifting procedures.

Safety Culture in Lifting Operations

Lifting safety is not the responsibility of the crane operator alone.

Everyone involved has a role in preventing incidents.

Everyone Has Stop-Work Responsibility

A worker who observes an unsafe condition should have the authority and confidence to raise the concern and stop the activity when necessary.

A strong safety culture encourages people to speak up before an incident occurs.

Do Not Normalize Unsafe Practices

Repeatedly performing an unsafe lifting practice without an incident does not make it safe.

The absence of an accident is not proof that the lifting method is acceptable.

Practical Example of a Lifting Incident

Consider a situation where a construction team needs to lift a heavy piece of equipment onto an elevated platform.

The load weight is known, but the rigging team selects slings based only on the load weight without considering the sling angle. During the lift, the load becomes unstable and starts tilting.

The operator stops the lift before an incident occurs.

The team then reviews the rigging arrangement, confirms the center of gravity, checks the sling configuration, and selects a more suitable lifting method.

This example demonstrates an important principle. A lifting operation should never continue simply because the load has already been attached to the crane.

How a Safety Officer Can Improve Lifting Safety

A Safety Officer plays an important role in monitoring lifting activities, but the Safety Officer should not replace the responsibilities of the competent lifting team.

Monitor Critical Controls

The Safety Officer can verify that key controls are in place, including:

• Approved lifting plan where required
• Competent personnel
• Suitable lifting equipment
• Valid inspection status
• Proper rigging
• Adequate exclusion zones
• Clear communication
• Suitable ground conditions
• Weather considerations
• Safe worker positioning

Intervene When Conditions Change

A lifting operation that was safe at the beginning can become unsafe when site conditions change.

For example, a sudden increase in wind, a change in the lifting route, or the arrival of another work crew may require the operation to be reassessed.

The Safety Officer should encourage the team to stop and reassess whenever significant conditions change.

Final Thoughts on Lifting and Rigging Safety

Lifting and rigging safety depends on preparation, competence, communication, equipment integrity, and disciplined execution. There is no single control that can make a lifting operation safe.

The safest approach is to plan the lift properly, understand the load, select suitable equipment, inspect all lifting accessories, establish an effective exclusion zone, maintain clear communication, and never allow production pressure to override critical safety controls.

A professional lifting team does not ask, “Can we lift this load?” They ask, “Can we lift this load safely, with the correct equipment, competent people, and proper controls?”

That mindset can make the difference between a successful lifting operation and a serious workplace incident.

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