Manufacturing & Engineering

Plan and carry out lifting operations safely

How to plan safe lifting operations under LOLER 1998 Regulation 8. Covers the roles of appointed person, crane supervisor, and slinger/signaller, lift plan contents, tandem lifts, and pre-lift checks.

UK-wide
Guide summary

Plan every lift with a competent person. Check equipment, ground conditions and weight. Supervise the lift and stop if unsafe. Follow LOLER rules to prevent injuries.

  • Plan every lift with a competent person
  • Check equipment condition and weight limits
  • Assess ground conditions and weather
  • Supervise the lift with a trained person
  • Stop the lift if conditions change
  • Use proper signals or radios for communication
  • Follow LOLER 1998 Regulation 8
  • Penalty: unlimited fine if rules are broken
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Every lifting operation must be properly planned by a competent person, appropriately supervised, and carried out in a safe manner. This is a legal requirement under LOLER 1998 Regulation 8, and it applies to every lift - from a routine warehouse pick to a complex multi-crane construction lift.

Failed lifting operations can cause catastrophic injuries and fatalities. Loads can fall, cranes can overturn, and workers can be struck or crushed. Proper planning prevents these incidents.

Lifting operations planning requirements

LOLER Regulation 8 requires that every lifting operation is planned to ensure it is carried out safely. The level of detail in the plan should be proportionate to the risk involved.

Key roles in lifting operations

Safe lifting operations depend on clearly defined roles with competent people in each position:

Appointed person: Plans the lifting operation. Must have practical and theoretical knowledge of planning lifts, including equipment selection, load assessment, and site conditions. For complex lifts, this is typically an experienced lifting engineer or crane coordinator.

Crane supervisor: Supervises the lifting operation on site. Responsible for ensuring the lift plan is followed, conditions are safe, and the operation proceeds correctly. Must have authority to stop the lift if conditions change.

Slinger/signaller: Attaches (slings) the load to the crane and provides signals to the crane operator. Must be trained in selecting appropriate lifting accessories, assessing load weight, and using standard hand signals or radio communication. Typically holds a recognised competence card (CPCS or equivalent).

Crane operator: Operates the lifting equipment. Must be trained and competent for the specific type of equipment being used. Must not operate the crane if they cannot clearly see the load or the signaller (unless radio communication is established).

Steps to plan a lifting operation

  1. 1

    1. Assess the load

    Determine the weight, dimensions, and centre of gravity of the load. Check for any factors that could affect the lift such as wind loading, load shift, or loose components. If the weight is not known, weigh the load or obtain reliable data from the manufacturer.

  2. 2

    2. Select the right equipment

    Choose lifting equipment and accessories with adequate Safe Working Load (SWL) for the load weight at the required radius. Check that thorough examinations are in date. Consider the lift height, radius, ground conditions, and any obstructions.

  3. 3

    3. Assess the site

    Check ground conditions, overhead obstructions (power lines, structures), wind exposure, and proximity to other operations. Ensure the ground can support the crane or lifting equipment including outrigger loads. Identify exclusion zones beneath and around the lift.

  4. 4

    4. Produce a lift plan

    Document the plan proportionate to the risk. A routine warehouse lift may need a brief method statement. A complex construction lift needs a detailed written plan covering: load weight, equipment selection and configuration, radius and height, ground bearing capacity, rigging arrangement, exclusion zones, communication method, sequence of operations, and emergency procedures.

  5. 5

    5. Brief all personnel

    Ensure everyone involved in the lift understands the plan, their role, and the communication system. Confirm that slingers, signallers, and operators are competent and hold appropriate certification where required.

  6. 6

    6. Carry out pre-lift checks

    Before the lift, confirm equipment condition, check rigging is correct, verify exclusion zones are enforced, check wind conditions against limits, and confirm the load weight matches the plan. The crane supervisor should authorise commencement.

  7. 7

    7. Monitor and supervise the lift

    The crane supervisor must monitor the operation throughout. If conditions change (wind increases, ground gives way, communication breaks down), stop the lift immediately. Do not resume until it is safe.

  8. 8

    8. Record and review

    After the lift, review what went well and what could be improved. For recurring lifts, update the method statement with lessons learned. Report any near misses or incidents.

Tandem and complex lifts

Tandem lifts (using two or more cranes to lift a single load) carry significantly higher risk and require specialist planning:

  • A suitably experienced appointed person must plan the lift - standard crane operators are not sufficient
  • Load share calculations must be accurate for each crane at every stage of the lift
  • All cranes must be compatible and able to communicate
  • A detailed written lift plan is always required
  • Rehearsal or walk-through of the lift sequence is recommended
  • A single person must coordinate and have authority over all crane operators

Other high-risk lifts requiring detailed planning include lifts near power lines, blind lifts (where the operator cannot see the load), lifts over occupied areas, and lifts in confined spaces.

Common problems

Load weight not confirmed: Estimated weights are a frequent cause of lifting failures. Always confirm the actual weight before lifting. Do not rely on assumptions.

Ground conditions not assessed: Crane outriggers can punch through soft ground, causing the crane to overturn. Use crane mats or spreader plates and verify ground bearing capacity.

Lifting accessories not checked: Slings, shackles, and chains must be inspected before each use and must have current thorough examination certificates. Discard damaged accessories immediately.

Exclusion zones not enforced: People must be kept clear of the area beneath and around the lift. Use barriers, banksmen, and signage to enforce exclusion zones.

Official guidance on lifting operations