Steelwork Factory

Lifting Operations Guide

January 2015

Steelwork
Factory Lifting
Operations Guide

Although care has been taken to ensure, to the best of our knowledge, that all data and information contained herein are
accurate to the extent that they relate to either matters of fact or accepted practice or matters of opinion at the time of
publication, The British Constructional Steelwork Association Limited, the authors and the reviewers assume no
responsibility for any errors in or misinterpretations of such data and/or information or any loss or damage arising from or
related to their use.

The British Constructional Steelwork Association Ltd.,

4, Whitehall Court, Westminster, London SW1A 2ES.
Telephone: +44(0) 20 7839 8566 Fax: +44(0) 20 7976 1634.
E-mail: postroom@steelconstruction.org Website: www.steelconstruction.org

Contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Typical Lifting Equipment Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Typical Lifting Accessories Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Typical Operations / Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Maintenance, Inspection and Thorough Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. Competent Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7. Initial Planning of the Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8. Competence of Crane Operator and Slinger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9. Selection and Suitability of Lifting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10. Pre-determined Lay-down Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11. Preventing Toppling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12. Carrying Out the Lifting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Appendices
1. Example Factory Lifting Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2. Example Risk Assessment - Factory Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. Example Daily Crane Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4. Example Risk Assessment - Stability of Plate Girders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. Example Lifting Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

STEELWORK FACTORY LIFTING OPERATIONS

1. Introduction
The use of cranes and lifting accessories is an essential part of the
workplace operations within steelwork fabrication factories. Lifting
operations should only be carried out by trained and competent
personnel and this guide is intended to provide useful information to
managers and supervisors of lifting operations in steelwork factories.
This guide details how intermediate or routine lifting operations are
planned, arranged and controlled within the steelwork fabrication
factory.

3. Typical Lifting
Accessories Used

Lifting chains

Wire rope

Fabric slings

Positive lifting aids

Plate clamps

Beam clamps including rotators

Magnetic lifting devices

Vacuum lifting devices

Reference

Lifting and spreader beams

BS 5744, Code of practice for safe use of cranes (overhead/underhung travelling and goliath cranes, high pedestal and portal jib
dockside cranes, manually-operated and light cranes, container
handling cranes and rail-mounted low carriage cranes).

Shackles

Eye bolts

Splitter hooks

BS 7121-1 Code of practice for the safe use of cranes.

Fish plates

This is a good practice guide for use with cab, pendant or radio
controlled electric overhead cranes and various lifting accessories.
This guide does not address lifting operations that are carried out
with Lorry Mounted Cranes and Mobile Elevating Work Platforms.

BS 7121-2:2012 Code of practice for the safe use of cranes Part 21: Inspection, maintenance and thorough examination - General.
BS 7121-2-7: 2012 Code of practice for the safe use of cranes Part
2-7: Inspection, maintenance and thorough examination Overhead travelling cranes, including portal and semi-portal
cranes, hoists and their supporting structures.
Lifting Operations and Lifting Equipment Regulations (LOLER).

4. Typical Operations / Tasks

The typical steelwork used may be black as it comes from the
stockist or blasted, fabricated or painted. This includes plate,
sections and tubes.

Lifting Operations and Lifting Equipment Approved Code of

Practice L113.

a) Lifting steel plates, sections, hollow sections and girders off and
onto shot blasting or metal-spray bogies, stillages, bearers or
supporting steelwork.

Provision and Use of Work Equipment Approved Code of Practice

L221.

b) Loading and offloading vehicles or trailers.

Supply of Machinery (Safety) Regulations.

c) Lifting palletised loads.

Management of Health Safety and Welfare Regulations and

Guidance.

d) Lifting steel plates and girders off and onto stiffening/welding

stillages, bogies, bearers or supporting steelwork.
e) Moving steelwork in and out of various machines including,
ending M/C, milling, T&I and robot.

2. Typical Lifting
Equipment Used

f)

Lifting steel plates from shot blaster outfeed rollers off and onto
profiling/drilling beds.

g) Lifting finished profiles and off-cuts from beds into skips and into
stock piles.

Forklift trucks

Side loaders

Pallet trucks (manual/powered)

Mechanical handling aids (eg magnets, lifting arms)

Powered rollers

Telehandlers

k) Offloading small transfer table (profiled plates), side-loader,

vehicles and sub-contractor vehicles.

Overhead gantry (pendant or remote)

l)

Semi-goliath

h) Loading and offloading plates from transfer table and grinding

machine rollers.
i)

Lifting steel sections off and onto saw-drill stillages.

j)

Varied lifts on small fabrication projects and basic shaped

maintenance items.

Lifting plate and box girders off and onto stillages, bogies,
bearers or supporting steelwork.

m) Turning girders down, erecting steelwork.

n) Lifting or turning steel plates, sections and girders off and onto
support stillages, vehicles, bearers or supporting steelwork.

STEELWORK FACTORY LIFTING OPERATIONS

o) Lifting or turning steel plates and sections off and onto support
stillages, vehicles, bearers, blaster rollers or bogies.
p) Lifting steel plates off and onto rollers or lorry beds.

5. Maintenance, Inspection
and Thorough Examination
Every employer shall ensure that before lifting equipment is put into
service for the first time by him it is thoroughly examined for any
defect or in accordance with an examination scheme.
It is important that lifting equipment is maintained in an efficient state
and in good order. A maintenance programme should be drawn up
for each item of lifting equipment. This work may be undertaken by
the in-house maintenance team if they have the necessary skills or
by specialist contractors. Records of maintenance activities should
be retained.
Inspections are typically undertaken as part of the planned
maintenance programme for the lifting equipment. It is
recommended that a written record of the inspections is kept and
made available to the competent person undertaking thorough
examination. Arrangements should be made to remedy any defects
found. It is important that any deterioration is picked up and remedied
in good time.

Lifting equipment should be thoroughly examined:

Where the lifting equipment has not been used before.

Where the safety of lifting equipment depends on the installation

conditions.

After installation and before being put into service for the first time.

After assembly and before being put into service at a new site or
in a new location.

If exposed to conditions causing deterioration which is liable to

result in dangerous situations.

At least every 6 months in the case of lifting equipment for lifting

persons or an accessory for lifting.

At least every 12 months in the case of other lifting equipment.

Each time that exceptional circumstances which are liable to

jeopardise the safety of the lifting equipment have occurred.

Further information on thorough examination and inspection can be

found in the BS 7121-2 series.

For intermediate and complex lifts where there are increased

hazards and risks the skills of the competent person (Appointed
Person) planning the lift will need to be greater. Training courses and
competency assessment for persons undertaking lift planning is
available from a number of providers. It is recommended that the
person responsible for planning lifting operations has undertaken
suitable training and that their competency can be demonstrated.
This would include any persons responsible for the initial selection
and provision of lifting equipment and accessories for general use
on the site.
'Appropriate supervision' means that it should be proportionate to the
risk and take into account the personnel involved in the particular
lifting operation, such as those with disabilities and the inexperienced
(an Example Risk Assessment is given in Appendix 2). Levels of
supervision are determined by the nature of the work and the
competence of those involved in using the equipment and assisting
with the lifting operation. It does not mean, for example, that an
experienced forklift truck driver will have to be under direct
supervision every time he carries out a routine lift, but he may need
to be supervised if he is required to lift an unusual load, or lift in
potentially hazardous conditions, eg across a public road.

7. Initial Planning of the Lift

The planning of individual routine lifting operations may be the
responsibility of those who carry them out (eg a slinger or crane
operator). But for much more complex lifting operations (eg a
tandem lift using multiple cranes), a written plan should be
developed by a person with significant and specific competencies adequate training, knowledge, skills and expertise - suitable for the
level of the task.
For straightforward, common lifting operations, a single initial
generic plan may be all that is required (eg forklift trucks in a factory),
which could be part of the normal risk assessment (an Example Risk
Assessment is given in Appendix 2) for the activity. However, from
time to time it may be necessary to review the plan to make sure that
nothing has changed and the plan remains valid. Routine lifting
operations which are a little more complex may, depending on the
circumstances, need to be planned each time the lifting operation is
carried out.
a) Weight and configuration of load
When lifting a load the weight and centre of gravity will be available
on the shop plan, if in doubt do not lift. A calculation of the weight of
the load can be made based on the estimated weight of steel being
7700 kg/m3 and using the formula Load Volume x Weight of Steel =
Load Weight.
b) Safe Working Limit (SWL) and Working Load Limit (WLL)

6. Competent Person
The person planning the operation should have adequate practical
and theoretical knowledge and experience of planning lifting
operations (an Example Factory Lifting Plan is given in Appendix 1).
For routine lifting operations the planning of each individual lifting
operation will usually be a matter for the people using the lifting
equipment, such as a slinger or the forklift truck operator, etc. The
person carrying out this part of the planning exercise should have
appropriate knowledge and expertise.

The SWL must be clearly visible on the lifting equipment. The WLL is
the maximum loading that a sling is rated to take in normal service
conditions, and the SWL is the maximum weight a sling is to handle
and should never be exceeded. The weight of the lifting accessories
must also be considered when assessing the total weight to be
lifted. The WLL should be clearly visible, the SWL is to be determined
by the lift planner/slinger and is to suit the method of attachment,
ie if you use a choke hitch to attach chains/strops then you lose 20%
of your lifting capacity.
c) Single, tandem or triple lift
Length, configuration and weight of load will determine whether a
single, tandem, triple or quadruple lift is used.

STEELWORK FACTORY LIFTING OPERATIONS

d) Basic lift

f)

This is a lifting operation where the weight and centre of the gravity
is known or can be simply established and there are no significant
hazards or obstructions in the area/route where the lift is to be
undertaken. Basic lifts should be carried out in accordance with the
factory lifting plan and operational procedures.

This is a lifting operation that

requires more than one crane to
lift the load, or cranes using load
enhancement accessories (such
as belt rotators), or when the
lifting operation is taking place in
an area with exceptional hazards.
Complex lifts will need a specific
lifting plan to identify any
exceptional or unusual risks, if
the same operation is to be
repeated then the plan should be
reviewed at regular frequencies.

Examples of basic lifts are:

i.

Single section, plate or tube lifted by the overhead electric crane

with chains and accessories moving along the established
access route to the resting place.

ii.

Offloading bundled steelwork components and palleted small

items from a delivery vehicle onto firm surrounding ground or
dunnage.

iii. Use of a telehandler, side loader or forklift truck on firm ground

to distribute bundled or individual components from site storage
to the workplace.

i.

Using two or more electric overhead cranes lifting and travelling

with large steel components into a workplace and manoeuvring
over machinery or access points.

ii.

The turning of a load with more than one crane.

iii. The turning of a load that is shaped such that the centre of
gravity is not obvious.

Examples of standard lifts are when:

iv. A lift operation involving the initial use of a dedicated designed

lifting frame.

i.

v.

ii.

An electric overhead crane is lifting and travelling with large steel

components into a workplace having to pass over production
machinery and access points.
Turning steelwork sections and fabricated items using a set of
chains.

iii. Turning steelwork sections and fabricated items using clamps.

iv. Lifting with the use of a spreader beam.
v.

Using two electric overhead cranes lifting and travelling with

large steel components into a workplace, but not over
machinery or access points.

Note: Tandem Lifting: The operational speeds (travel and hoisting)

need to be similar to avoid excessive stopping and starting of the
faster crane. A task specific lift plan is required for a tandem lift. The
competent person planning the lift should establish the load that will
be taken by each crane and ensure that there is sufficient margin
(factor of safety) between the load and the rated capacity. As a
general rule the load on any individual crane should not exceed 75%
of the rated capacity. Where there is any doubt as to the weight of the
component to be lifted, or the weight distribution (centre of gravity),
load cells should be fitted between below the hook of each crane.

Loading using Magnets and Spreader Beam

Tandem Lift with Turning Belts

Examples of complex lifts are:

e) Intermediate lift
This is a lifting operation where there are significant hazards, either
within the working area of the crane or on the access route to the
working area. Intermediate lifts should be carried out in accordance
with the factory lifting plan and operational procedures.

Complex lift

Lifting of personnel.

vi. It is recommended that the competent person who has planned

the lift (Appointed Person) is present the first time a complex lift
is undertaken
The competent person should periodically review lifting operations
that are being undertaken on the site to assess if there have been any
changes or new hazards. The Site Lifting Plan should be reviewed
and updated as required. Employees should be encouraged to
contact the competent person if they have any concerns as to the
general Site Lifting Plan or any task specific lifting plan.
In exceptional circumstances three cranes can be used together for
a triple lift. These are classed as complex lifts and can only take
place in the presence of and with the authorisation of a Lift
Supervisor (or Appointed Person); these lifts must include the use of
one or more load cells or strain gauges. By way of example it is
possible to link some cranes together with the 30t spreader beams
to form 2 x 30t lifting points in a tandem rig set-up. The location and
capacity of the lifting lugs must be checked prior to any lift
commencing.
Should there be any doubt in categorising a lift; then further advice
will need to be given by the Competent Person.

STEELWORK FACTORY LIFTING OPERATIONS

8. Competence of Crane
Operator and Slinger

9. Selection and Suitability

of Lifting Accessories

All crane operators will be assessed both internally and externally

after a period of training to confirm their competency.

Lifts can be carried out using accessories such as shackles

attached to welded or bolted lifting lugs, or the use of suitable
capacity grabs, chains, wire, woven or nylon slings. Use the correct
accessories for the load and take account of the weight of the
accessories when calculating the total load to be lifted. Consider the
length of the load to be lifted to ensure the most appropriate length
of accessories (chains or woven nylon slings) is used to maintain the
correct angle and that the working load limit is not exceeded.

a) Some of the key elements for crane operators are:

Understanding the risks and hazards associated with the work.

To be able to demonstrate both theoretically and practically the

use of radio controlled/pendant operation and slinging methods
to move loads.

Explaining and demonstrating the range of movement of radio

controlled/pendant cranes.

Planning of method to be used in moving load.

Safe loading rules (weight, height, clearance etc).

Workshop practice when using radio controlled / pendant crane

including the use of hand signals.

Safety of others in workshop area.

Teamworking.

Pre operational checks (see Example Daily Crane Checks

Appendix 3).

10. Pre-determined
Lay-down Area
Before any lift commences, a lay-down area should already be
selected ensuring there is sufficient room and sound bearers or
supports. Consideration should be made as to the avoidance of
other risks such as working at height to remove the slings on
completion of the lift. Further guidance is available in Safety in the
Storage and Handling of Steel and other Metal Stock HSG246.

b) Some of the key elements for slingers are:

Understanding the risks and hazards associated with the work.

Selecting and using lifting accessories.

Selecting and using wire rope slings.

Using 'Safe Working Load' charts.

Slinging and moving loads.

Working with cranes.

The weights and centres of gravity of loads and taking these

factors into account of slinging and moving same.

Working knowledge of all relevant current legislation relating to

lifting and slinging and of general site and workshop safety
standards.

Lifting tackle inspection, maintenance and storage procedures.

c) Some examples of the accredited training course providers

are listed below:

ITSSAR (Independent Training Standards Scheme and Register).

NPORS (National Plant Operators Registration Scheme).

RTITB (Road Transport Industry Training Board).

ALLMI Slinger/Signaller (Association of Lorry Loader

Manufacturers and Importers).

AITT Registered Scheme Accredited Operator (Association of

Industrial Truck Trainers).

CPCS Trained Operator Red (Construction Plant Certification

Scheme).

CPCS Competent Operator Blue.

NVQ Constructional Steelwork Operations.

NVQ Lifting and Moving Loads.

LEEA (Lifting Equipment Engineers Association).

11. Preventing Toppling

Fabricated steel components can be irregular in shape and size and
the centre of gravity may not always be obvious, therefore it may be
necessary to have risk assessments associated with works handling
procedures including the use of cranes (Example Risk Assessment
- Stability of Plate Girders Appendix 4).
The greatest risk is to the crane operator in charge of the cranes
remote control and, in known cases, the use /misuse of the crane /
chain combination has resulted in the toppling of a steel component.
In such circumstances the operator and colleagues can be found in
the line-of-fire (in a position where there is no escape from when
something unplanned happens). Another common hazard
associated with the landing of fabricated steelwork is the failure to
pull free by hand the accessories from under the fabricated
component. If the lifting accessories (chains) are dragged from under
the fabricated component by raising the chains mechanically there is
a greater risk of the chains snagging the bottom of the fabricated
component, work bench or bogie and causing it to topple over.
Only trained and competent operators should use cranes and lifting
accessories for the handling, moving and turning of fabricated steel
components.
Risk assessments
In terms of the risk assessment (RA), the first issue that arises is the
extent that the RA should deal with the risks arising from the
hazard as the harm can be significant in such cases. It is
reasonable that the following case studies should be considered:
Case study 1:

Trainees or young people should be fully supervised during lifting

operations until a successful competence assessment is completed.

An 8-tonne plate girder firmly standing on dunnage on the shop floor

is toppled when the chains are dragged from under the load by the
crane being driven upwards, the chain or hook snagged the bottom
flange causing the girder to topple.

STEELWORK FACTORY LIFTING OPERATIONS

Such was the force exerted by the crane/chain combination) the

procedure can overturn or displace virtually any object in its path.
Although the propensity for the plate girder to topple would not be
the most significant factor, the 8-tonne plate girder was
approximately 3.5 times as high as the width of the flange on which
it was stood ie an aspect ratio (AR) of 3.5.
In such a case the procedure might be termed deliberate misuse?
Case Study 2:
A portal rafter component is toppled as it stood with its haunches
upward (waiting for the longitudinal welding of the haunch to the
rafter beam). In terms of approximate geometry the dimensions of
the 1.5-tonne rafter were such that its maximum vertical height
including haunch was 6 times the width of the beam flange on which
it was stood ie an AR of 6.
In this case the situation does depend on the propensity for the
component to topple. This is based on the fact that some
components stood alone and vertically are relatively easy to topple.

12. Carrying Out the Lifting

Operation
a) Establish centre of gravity
By either measuring or stepping-out equal distances if the load is
uniform in shape or size.
In some circumstances the lift points are already determined by the
use of welded or bolted lugs. These lugs are positioned on the items
to be lifted at the correct centres after fabrication is completed.
Shackles attached to lifting lugs top side of top flange is the
preferred method. The crane hook should always be positioned over
the centre of gravity.
b) Carry-out pre-user checks (Appendix 3 Example Daily
Crane Checks)
An inspection of the crane and lifting accessories to be carried out
prior to lifting operation commencing to ensure the equipment is in
good condition and indicated with a current thorough examination.

Therefore in context, two other examples might be considered:

c) Crane pre-use checks:

Universal Column (UC) with an AR of 1; and

1.5m deep truss with 150x150 SHS booms having an AR of 10.

The UC is self-evidently not susceptible to toppling, just as it is selfevident that it would be necessary to stabilise such a truss if
positioned vertically awaiting further work. The question is what AR
between 1 and 10 should be used to determine whether a
component is sufficiently self-stable to not require additional secure
restraint.
Another factor that may be important is the length of the component
relative to the spacing of the supports being the length of a bogie,
or the distance between static trestles or between wooden spacer
blocks for components placed directly on the shop floor (dunnage).
If a component is relatively a lot longer than the spacing of the
supports, it is more likely to assume a lop-sided attitude that will
increase its propensity to topple. In such a case additional security
clamps may be required.

General visual condition.

Isolation switch.

Long travel.

Cross travel.

Brakes.

Pendant or remote control.

Hoist ropes.

Hook and safety catch.

Hoist upper limit switch.

Hoist lower limit switch.

Hoist brake.

d) Sling pre-use checks:

Recommendations

Safe working load marked on the sling.

That additional restraint should be considered for all components

(above say 50kg piece weight) positioned vertically if their AR
exceeds 4. This rule means that beams from Universal Beams (UB)
may be considered sufficiently self-stable, whereas many haunched
rafters based on the same UB would not be so if stood with the
haunch upwards. For irregular components it is recommended to
make specific consideration of the centre of gravity and the potential
pivot point if toppling is to occur.

Safe working load is greater than the weight of the load to be

lifted.

The chain legs are the same length.

No visible damage to chain links.

The sling/strop is in good condition (no cuts, burns or

excessive wear).

There are no broken ends in wires (for wire ropes).

Check to see that there is no chafing of wire ropes.

It is also recommended that the RA includes the consideration of the

propensity of components to topple in the works handling
procedures and to consider in the RA a maximum length limit for
components to be placed on bogies without additional secure
restraint.

e) Check for proximity hazards

Before commencing lift ensure that there are no obstructions,
eg other work equipment or structures that may prove hazardous
during the lifting operation. The load should never be intentionally
lifted over the top of personnel if any activities need to be stopped
before the lift commences then the crane operator must ensure this
takes place before commencing the lift.
f)

Confirm direction and route to lay-down area.

Access the route that the load and crane operator will travel. Ensure
that the walking route is clear of any trip hazards and that load has
no height restrictions. Always keep the load in front of you and as low
as practicable during travel.

STEELWORK FACTORY LIFTING OPERATIONS

g) Check visibility and environmental conditions

Ensure that there is a clear line of sight between the start and finish
of the lifting operation. Radio control boxes have a long operating
range; operator should stand a safe distance from load but still stay
in close visual contact. Additional care should be taken when
operating the cranes at night or in poor light conditions as vision may
become impaired. Where the crane operates outside the building
lifting operations can be affected by adverse weather such as high
winds and specific procedures will be needed to address the safe
operation in such conditions.
h) Attach load correctly
The slinger is responsible for attaching/detaching the loads to the
lifting equipment, lifting accessories must be compatible. Ropes,
chains or slings should only be shortened in a safe manner by
following the manufacturers guidance. Check for any sharp edges
and protect the slings where necessary. ENSURE THE LOAD IS NOT
SECURED TO THE BENCH OR FLOOR BEFORE LIFTING.
i) Lift and transfer the load
Lifting and travelling with the load should be carried out in a smooth
motion without any jerking or erratic movements.

m) Stacking of material / stock

All material should be stacked on firm even ground, on dunnage or
steel packing, the greatest influence on the type of stacking used in
the storage area is the type of crane accessory used to place and
remove the materials, whether magnetic beams are used or
spreader beams with chains and plate clamps.

Where overhead cranes have been fitted with inverters to ramp-up

and down travel speeds refer to specific risk assessments and
procedures when operating.

Plates should be stacked with a slight step back at the front to

enable identification marks to be accessible.

Carry out a trial lift first to ensure the centre of gravity has been found
and that no snagging of the load is present.

Large/wide sections can be stacked by interlocking the flanges but

should not be stacked higher than 2 metres in height.

The operator/slinger should ensure they and any others in the area
are at a safe distance from the load in case something unexpected
happens at the start and during the lift.

Narrow/slim sections may need to be stacked in a pyramid shape to

maintain stability. The height of the pyramid will be determined by the
base width and larger sections should not be stacked over the top
of smaller sections (as the pile goes up it becomes unstable). The
pyramid should never be climbed to reach the upper level.

When cranes are used in tandem check if they can be operated from
one remote control box and by one operator on slow travel speed
only. If not, establish a good communication system between the
two operators.
j)

Position the load

The load should be lowered and positioned at the pre-determined

lay-down area onto suitable bearers or supporting steelwork
ensuring nothing is trapped underneath, the load is stable and the
lifting tackle can be removed safely and easily. Chains and slings
must never be trapped under the load and if this occurs then ensure
that they are never dragged from under a load by the crane.
k) Remove the lifting accessories
Lifting accessories should only be removed when the slinger is
satisfied that the load is stable and the full weight is on the dunnage
or supporting steelwork. Chains, slings or wires should not be pulled
off the load by using the crane hoist or travel, as this can cause the
load to topple. All unnecessary work at height should be avoided by
the slinger. The accessories should be pulled by hand from under
the load to allow the accessories to be raised clear of the working
area. Do not drive the chains out from under the load as snagging
can occur.
l)

Where dunnage is used to span across the flanges, support will be

needed in the web to prevent a guillotine effect on the dunnage.
Hollow sections and tubes will need to be stacked within vertical
posts to prevent uncontrolled movement of the stack.
n) Turning sectional and fabricated steel
Two chains (a single chain can be used for smaller shaped pieces
ie passing through a hole) should be used close to the point of
centre of gravity and within the permitted angle of the diagonal
opposed legs; this should lift the load clear of the ground and also
maintain a balanced/level lift. Where the length of the load creates a
severe arching the turning operation will not be possible, therefore a
spreader beam may be required. The chains bight should be
positioned to ensure the load is only turned a quarter turn and then
grounded each time to enable the chains to be re-set for the next
turn. Do not allow the load to snatch the chains as this causes shock
loading and can result in damage.

Storage and maintenance of the lifting accessories

Lifting accessories should be stored in conditions that do not lead to

damage or deterioration.
Storage racking and handling systems must be maintained in an
efficient state and in good repair as equipment can quickly be
subject to significant wear and tear even with the most careful use.

STEELWORK FACTORY LIFTING OPERATIONS

1. Position the bight to offset the vertical before lifting and allowing the load
to swing slightly before laying down the section. A lay-down area should
already be selected ensuring there is sufficient room and sound bearers
for supports. Timber bearers are preferred for turning operations to reduce
the risk of slippage.

2. The bight is now set in the centre of the top flange and the load is gently
lifted towards vertical. Allow the load to settle in the upright position.

3. This in an example of incorrect positioning of the hooks when making a

bight on the chains, as the opening should face away from the centre of
the load.

4. This is the correct positioning of the hooks when establishing a bight on

the chain. Allow the load to settle in the upright position, before setting
down onto the bearers.

Examples of other lifting techniques are given in Appendix 5.

10

STEELWORK FACTORY LIFTING OPERATIONS

Example Factory Lifting Plan

Appendix 1

Company:

Reference no:

Works location:

Date:

Type of lifting equipment:

Type of lift:

single/worst case/manriding

Date and duration of lifting operation:

Details of working area/where
equipment will be sited or regularly
operated [attached sketch if appropriate]
Name of hire company: (If applicable)
Name of lift supervisor:
Name of slinger/signaller [if multiple
series of lifts at different location name
all slinger/signallers]:

a]
b]
c]

Method of communication:

radio/hand signals/other [please specify]

Lift details

Description of load to lifted

Max weight of load as advised

kg

kg

kg

kg

Radius at which load is to be placed

Boom length to be used [if applicable]

Safe working load capacity at given radius

kg

kg

kg

kg

Weight of hook block[s] lifting equipment

and extensions [if available]

kg

kg

kg

kg

Maximum available lifting capacity for

load to be lifted

kg

kg

kg

kg

Acceptable

YES / NO

YES / NO

Details of lifting gear [attach sketch if appropriate]

YES / NO

YES / NO

SWL

Details of risk assessment:

[Note: This lift plan MUST be accompanied by an assessment of the risk present by the proximity hazards identified below]
Adjacent structures

Overhead cables

Service covers

Underground services

Other lifting equipment

Ground conditions

Access/egress routes

Third Parties

Railway lines

Excavations

Width restrictions

Other hazards

Specify:

Authorised by:

[Lifting operations co-ordinator]

Date:

The supervisor/slinger must ensure the following checks are made and recorded on the appropriate form.
Certificate of test for lifting equipment
Certificate of thorough examination for lifting equipment and gear
Register of weekly inspection for lifting equipment
Plant operators certificate of competence and performance if unknown
Slinger/signallers certificate of competence and performance if unknown
Other equipment specific checks specified on the relevant form

11

STEELWORK FACTORY LIFTING OPERATIONS

Example Risk Assessment - Factory Lifting Operations

HAZARD

Untrained
operators

ACTIONS
(Eliminations, Substitutions and Controls)
All operators MUST be trained in the safe use of overhead cranes before using them.
Contractors MUST NOT use cranes without proof of training on overhead cranes.

Appendix 2
WHAT FURTHER
ACTION IS NECESSARY
Training to be completed
by all employees before
they use the equipment.

All lifting equipment must be thoroughly examined every 6 months or sooner if damage has occurred.
Colour coded tags to be fitted to all lifting equipment, denoting the latest inspection period.
NO equipment to be used without the relevant colour coded tag attached.
Slings / Chains
Clamps / other
attachments

ALL lifting equipment to be placed on racks/hooks provided when not in use, do not leave on the floor.
Chain hooks to be returned to the chain ring when not in use.

An up-to-date schedule of
equipment to be
maintained.

All equipment should be checked before use.

Chains NOT to be left on the work piece when welding unless it is for safety reasons ie a large beam being
held in place.

Supervisor to monitor and

ensure compliance

When holding work for welding, turn off power to the crane and attach an earth to the work piece.
A polyester strop is to be used between the crane block and the chains to prevent earthing through the crane.
Correct slinging techniques to be used by trained competent personnel.
Work within S.W.L on all cranes and lifting equipment.
Use correct colour coded equipment.
Falls of material

Use a spreader beam when lifting long loads according to manufacturers recommendations.

Supervisor to monitor and

ensure compliance.

Maintenance schedule to be in place.

Where contractors are used ensure they are trained/competent.

To be audited

Complete a test lift ie lift a few cm off the trestle/floor to make sure the load is central and the load does
not swing.
Stand clear of the load when it is being lifted do not put yourself in a position where you could be trapped.
Remote control used for the overhead cranes, operator to ensure that they are well clear of a load when lifting
or lowering into position.
Entrapment

If a pendant is to be used take extra care/time to ensure that you do not put yourself in an unsafe position,
get help if required.

Supervisor to monitor and

ensure compliance.

DO NOT stand between steel when lifting/moving or turning eg within an area of entrapment if the load swings
towards you.
Maintenance schedules to be set up for all cranes.
Scheme of work for crane structure required.
Maintenance

Only use approved contractors for maintenance.

Competent contractors to
be used.

A thorough examination MUST be conducted every 12 months for every crane by a competent inspector.
DO NOT traverse a loaded crane over the top of other people.
Moving loads in
the workshop

Crane operator
checks

Ensure that there are no other cranes in the way of your route, plan your route. keep a safe distance from other
cranes ie 2m.
Before use, checks of the chains or lifting equipment are to be undertaken by all operatives each time they use
the crane.

Supervisor to monitor and

ensure compliance.

To be audited.

Supervisors to perform daily recoded crane / equipment checks.

Lift plan

A specific lift plan MUST be used for items that are not covered by the generic lifting plan eg lattice girders or
unusual shapes and when holding the steel with a crane for welding.

To be audited.

Turning of steel MUST be completed with two chains attached.

The area MUST be clear of other personnel.
Turning steel
beams

You MUST assess the weight and size of the steel and use the correct lifting equipment.
Do NOT snatch the load causing a shock load.
Untrained personnel must NOT turn steel.
ONLY turn the steel the minimum number of times.

12

To be included in the
training course.

STEELWORK FACTORY LIFTING OPERATIONS

Example Daily Crane Checks

Appendix 3

1.

Identify the crane to be used.

2.

Identify bay the crane is in.

3.

What is the Safe Working Load of the crane.

4.

Check the remote control is working correctly.

5.

Carry out a visual inspection of the crane prior to starting, observe the structure, cable systems etc. Is it working correctly?

6.

Release the emergency stop button and start the crane.

7.

While operating a crane function, press the e-stop button to check that the emergency stop circuit works correctly.

8.

Re-start the crane and check the operation of the hoist and lower motion limit switches, do this using the SLOW speed.
Do not rely upon limit switches. Is it working correctly?

9.

Check the operation of each motion in turn, in slow then fast speed.

10. During the above make sure all brakes function correctly.
11. Lower the hook to just above ground level.
12. Carefully check the condition of the hook/block and hoist rope. Is the rope/hook/block free from damage?

Example Risk Assessment - Stability of Plate Girders

What are you already
doing?

What further action is

necessary?

Appendix 4

Action by whom Action by when

What are the hazards?

Who might be harmed

and how?

Crane chains striking

fabricated components or
equipment

Crane operator and others in Operators trained to ensure Tool Box Talks to remind
the lifting chains are properly operators of the hazards
the immediate work area
hooked back onto the main
ring and steered clear of all
fabrications and machinery.

Universal beam toppling

Universal beams rested on

Crane operator and
others in the immediate work stable benches or dunnage
area if girder topples from
bench

Operators trained to ensure Supervisor and

the lifting chains are properly Operator
hooked back onto the main
ring and steered clear of all
fabrications and machinery.

Regular inspection

Plate girder with haunch

toppling

Crane operator and others in Plate girders with haunch in

the upright position.
the immediate work area if
Consider the total height
girder topples from bench
against the width of the
base flange.

If the height is more than four Operator

times the width of the bottom
flange, then additional
security should be attached
to the bottom flange

Regular inspection

Plate girder or universal

beam toppling during transit

Operator and others in the

immediate work area if
girder topples from bogie
during transit

Plate girders with excessive

overhang may need to be
spread across more than
one transit bogie

Additional packing under the Operator

bottom flange where they do
not touch the bogie and
secure if the height is more
than four times the width of
the bottom flange

Regular inspection

Additional packing to be
used to maintain the
component in a stable
position

Specific jigs may be needed

that are secured to the
bench

Operator and others in the

Fabricated components
where the centre of gravity is immediate work area if the
fabricated component
not obvious
topples

Supervisor

Supervisor and
Operator

Regular inspection

Regular inspection

13

STEELWORK FACTORY LIFTING OPERATIONS

Example Lifting Techniques

Magnetic end plate lifter

Magnetic spreader beam for plate lifting

14

Appendix 5

Rotating belts tandem lift that

Magnetic clamp for single lifts

turns a section

(angle lifting version)

Basket hitch

STEELWORK FACTORY LIFTING OPERATIONS

Acknowledgements
BCSA would like to thank the following members for
their participation in the preparation of this guidance:
Nicholas Atkin

Severfield (Design & Build) Ltd

Robert Hall

Adey Group Ltd

Nicola Horton

William Haley Engineering Ltd

Brian Hughes

William Hare Ltd

Chris Johns

Cleveland Bridge UK Ltd

Heath McHugh
Alan Newman

John Reid and Sons (Strucsteel) Ltd

Tony Power

Elland Structural Steel Ltd

Kevin Rowe

Mabey Bridge Ltd

15

Steelwork Factory
Lifting Operations Guide
January 2015