Best Practices for Managing Safety Around Lifting Devices

Lifting devices, such as cranes, hoists, forklifts, and other mechanical equipment, are essential in many industries, including construction, manufacturing, and warehousing. However, these powerful machines also pose significant risks to both operators and other workers if not used properly.

Properly managing safety around lifting devices is critical to preventing injuries, equipment damage, and accidents.

This article outlines best practices for ensuring safety when operating and working around lifting devices.

1. Understanding the Hazards of Lifting Devices

Lifting devices are designed to move heavy loads, but if improperly operated or maintained, they can lead to accidents such as load drops, equipment failures, and collisions. Hazards associated with lifting devices include:

• Overloading: When a device exceeds its load capacity, it may result in equipment failure or tipping.
• Load Instability: Improperly secured loads can shift or fall during lifting.
• Equipment Malfunctions: Faulty components or lack of maintenance can cause failures.
• Operator Errors: Poor training or lack of attention can lead to accidents.
• Struck-By Hazards: Workers near the lifting device may be struck by moving parts or falling loads.

Recognizing these hazards is the first step toward establishing a culture of safety around lifting devices.

2. Training and Certification of Operators

One of the most effective ways to manage safety around lifting devices is ensuring that only trained and certified personnel are allowed to operate them. Operator training should cover:

• Safe Operation Techniques: How to control the lifting device safely, including starting, stopping, and maneuvering loads.
• Load Capacity Awareness: Operators must understand the load limits of the equipment and how to assess whether a load is within safe parameters.
• Pre-Operation Inspections: Proper procedures for checking equipment before each use to ensure it is in safe working condition.
• Emergency Procedures: How to respond in the event of equipment malfunction or an accident.
• Worksite Communication: The importance of communicating clearly with other workers, particularly when maneuvering loads in busy environments.

Tip: Require all lifting device operators to undergo periodic refresher training to stay up to date on safe practices and regulations.

3. Conducting Regular Inspections and Maintenance

Lifting devices require regular inspections and maintenance to ensure they operate safely. A structured inspection and maintenance program helps identify potential problems before they lead to accidents. Maintenance teams should perform the following:

• Pre-Use Inspections: Operators should perform a visual inspection before using the lifting device each day. This should include checking cables, slings, hooks, controls, and safety devices.
• Scheduled Maintenance: Follow the manufacturer’s guidelines for routine maintenance, including lubrication, part replacement, and overall system checks.
• Testing Load Limits: Periodically test the device to ensure it can still safely handle its rated load.
• Documenting Inspections: Keep detailed records of inspections and maintenance activities to ensure compliance with safety regulations and identify recurring issues.

Tip: A comprehensive maintenance log allows operators and safety managers to track the condition of each piece of equipment and schedule necessary repairs proactively.

4. Proper Load Management

Safe load handling is a fundamental aspect of managing lifting devices. Improperly loaded equipment is one of the leading causes of accidents involving lifting devices.

Key Load Management Practices:

• Understand Load Capacities: Never exceed the rated capacity of the lifting device. Refer to the equipment’s load chart or capacity labels to ensure the load is within safe limits.
• Balance the Load: Ensure that loads are balanced and secure before lifting. Unstable loads can shift during movement, leading to equipment tipping or load drops.
• Use Appropriate Slings and Attachments: Select the correct lifting slings, hooks, or attachments for each load. Make sure these tools are properly rated for the weight and type of load being lifted.
• Avoid Sudden Movements: Sudden jerking or rapid lifting and lowering motions can destabilize loads. Move slowly and steadily to avoid swinging or dropping the load.

Tip: For complex lifts, involve a qualified rigger to secure the load properly and ensure safe lifting operations.

5. Clear Communication and Signaling

Effective communication between operators and workers on the ground is critical to prevent accidents. Lifting operations often involve multiple team members, and poor communication can lead to confusion and dangerous situations.

Best Practices for Communication:

• Use Hand Signals: In noisy or busy environments, clear hand signals should be used to direct the operator. Standard hand signals for lifting operations, such as those specified by OHS regulations, should be followed.
• Radio Communication: In larger worksites, two-way radios are often necessary to ensure direct communication between the operator and workers involved in the lifting operation.
• Spotters: Assign a spotter or signal person to guide the operator in areas with limited visibility or where obstacles may block the operator’s view.
• Establish a Clear Work Zone: Ensure that the lifting area is clearly marked, and unauthorized personnel are kept out of the danger zone.

Tip: Train workers in proper hand signals and communication protocols to ensure everyone understands how to communicate effectively during lifting operations.

6. Implementing Lockout/Tagout (LOTO) for Lifting Devices

Lockout/tagout (LOTO) procedures are essential when performing maintenance or repairs on lifting devices. LOTO ensures that equipment is de-energized and cannot be accidentally activated during service.

LOTO for Lifting Devices Involves:

• Shutting Down the Device: Ensure that the lifting device is fully powered down and disconnected from its energy source.
• Applying Lockout Devices: Use lockout devices to physically prevent the equipment from being powered on.
• Tagging the Equipment: Attach a tag that clearly indicates the equipment is under maintenance and should not be operated.
• Verifying Deactivation: Before beginning maintenance, confirm that the lifting device is completely de-energized and will not move.

Tip: Always follow LOTO protocols when working on any lifting device to prevent accidental startup during maintenance.

7. Establishing a Safe Work Zone

Creating a designated safe work zone around lifting devices is critical to protecting workers from moving equipment and loads. This ensures that only authorized personnel are in the vicinity during lifting operations, reducing the risk of accidents.

Steps to Create a Safe Work Zone:

• Mark Boundaries: Use barriers, tape, or signs to establish a clear perimeter around the lifting area. Only authorized personnel should be allowed inside the work zone.
• Control Access: Limit access to the lifting area during operations to prevent workers from inadvertently walking into hazardous zones.
• Use Spotters and Traffic Controllers: In high-traffic areas, assign spotters or traffic controllers to ensure that lifting operations do not interfere with pedestrians or vehicles.
• Keep the Area Clean: Ensure that the lifting area is free from clutter, debris, or any obstacles that could interfere with equipment movement or create tripping hazards.

Tip: Conduct regular safety meetings to remind all workers about the importance of respecting the boundaries of safe work zones around lifting devices.

8. Emphasizing Ergonomics and Safe Lifting Practices for Workers

In addition to mechanical lifting devices, many workers still perform manual lifting tasks. Improper manual lifting can lead to musculoskeletal injuries, which can be prevented with the right practices.

Manual Lifting Best Practices:

• Assess the Load: Before lifting, assess whether the load is too heavy to lift alone. Ask for assistance or use a mechanical lifting device if needed.
• Use Proper Lifting Techniques: Lift with your legs, not your back. Keep the load close to your body and avoid twisting or bending at the waist.
• Take Frequent Breaks: For jobs that require repetitive lifting, ensure that workers take regular breaks to avoid overexertion and fatigue.

Tip: Implement ergonomic training programs to teach workers how to lift safely and reduce the risk of injuries caused by manual lifting tasks.

Managing safety around lifting devices requires a combination of proper training, regular equipment inspections, effective communication, and strict adherence to safety protocols. By implementing these best practices, employers can significantly reduce the risk of accidents and injuries related to lifting operations. Safety should always be the top priority, ensuring that workers and equipment are protected at all times.

Establishing a proactive safety culture around lifting devices not only keeps employees safe but also helps maintain productivity and operational efficiency in any workplace where heavy lifting is a daily requirement.