Contents

1. Foreword 1

2. Common accidents in lifting operations 2

3. Legislative requirements and code of

practice of lifting operations 2

4. People 3

5. Machinery 5
5.1 Cranes 6
5.1.1 Mobile crane 7
5.1.2 Tower crane 8
5.2 Lifting gears 9
5.2.1 Wire rope slings 9
5.2.2 Wire rope slings – cable clip 10
5.2.3 Chain slings 11
5.2.4 Shackles 12
5.2.5 Eye bolts 13
5.2.6 Hooks 14
5.2.7 Rings, links, swivels 15
5.2.8 Spreader beams 15
5.2.9 Chain mesh slings and fibre slings 15

6. Load 16

7. Method 17

8. Environment 18

* This booklet is also available in Chinese version

19
 1. Foreword
The lifting of objects generally occurs on construction sites, in factories and other
industrial situations. Correct lifting can move large objects efficiently and reduce manual
handling operations. Incorrect lifting however, can lead to disastrous accidents. Every
year, incorrect lifting procedures cause injuries, loss of work time and property. People,
machinery, loads, methods and the work environment, are all important factors for
correct lifting. Provided that enough safety measures are fully implemented, lifting
accidents can be reduced.

1
 2. Common accidents in lifting operations

• Overturning of the crane • Falling objects

• Breaking the
boom sling

• Touching overhead • Collision with obstacles

power lines

3. Legislative requirements and

code of practice of lifting operations
Local legislative requirements that apply to lifting operations include Factories and Indus-
trial Undertakings (Lifting Appliances and Lifting Gear) Regulations enforced by the Labour
Department, and Shipping and Port Control (Cargo Handling) Regulations enforced by the
Marine Department.

The Labour Department also published the code of

practice for "Safe Use of Mobile Crane and Tower
Code of practice
Crane" in 1998, and provides the trade with guidance
for the safe use of cranes.

2
 4. People
Personnel related to the lifting operation include "competent examiner", "competent person",
"crane operator", "slinger", "signaler" and others working nearby.

• The "competent examiner" is responsible for

regular examinations of the lifting appliances
or lifting gears. He shall be:
– appointed by the employer or the owner of
the lifting appliances/lifting gears;
– a registered professional engineer within a
relevant discipline;
– properly trained with relevant practical
experience.

• The "competent person" is responsible for

regular inspections of lifting appliances or
lifting gears. He shall be:
– appointed by the employer or the owner of
the lifting appliances/lifting gears;
– properly trained with relevant practical
experience.

• The "crane operator" is responsible for

operating the crane correctly and safely.
He shall:
– be at least 18 years of age and hold a
valid crane operation certificate;
– be physically fit;
– be familiar with hand signals for
communication.

3
 • The "slinger" is responsible for attaching and detaching the load to and from the crane.
He shall:
– have received appropriate training on general safe lifting operations;
– be capable of selectings lifting gears suitable for the loads;
– liaise with the operator and direct the movement of the crane safely.

• The "signaller" is responsible for relaying the signal from the slinger to the crane operator.
He shall:
– have received appropriate training on general safe lifting operations;
– be able to direct the movement of the crane and loads.

Suggested hand signals

Move away from the Move towards the

Emergency stop Stop Ready to move signalman signalman

Move slowly by Move towards the hand Move towards the hand Swing towards the hand Swing towards the hand
indicating distance stretched direction stretched direction stretched direction stretched direction

Raise the boom and

Raise the boom Raise the boom slowly Lower the boom Lower the boom slowly lower the load

Lower the boom Extent the boom Retract the boom Use the main hoist Use whip line
and raise the load

Lower the hoist Lower the hoist slowly Raise the hoist Raise the hoist slowly Stop every thing

Note: During the lifting operation, either the slinger or signaller shall communicate with
the operator. Other communication methods (e.g., wireless walkie-talkies,
4 telephones, etc.) may also be used.
 5. Machinery
Machinery – refers to lifting appliances and all lifting gears.

The lifting appliance includes a crab, winch, teagle, pulley block, gin wheel, crane, shearleg,
excavator, pile driver, pile extractor, dragline, aerial rope way, aerial cableway transporter
or overhead runway, etc.

The lifting gears includes a chain sling, rope sling, ring or similar gear, link, hook, plate
clamp, shackle, swivel or eyebolt.

5
 5.1 Cranes

Selection of cranes
For the correct selection of cranes, the following factors shall be
considered:

• Weights and dimensions of loads

• Height of lift and distances/areas of
movement of loads

• Number and frequency of lifts

• Period of time for the
lifting operation

• Ground conditions
• Other factors

Testing, examination and inspection

All testing and examination of cranes must be carried
out by competent examiners and the regular inspections
completed by competent personnel. All testing,
examination and inspection reports and certificates shall
be properly kept.

Safe Working Loads

The Safe Working Load (SWL) for operating the crane shall be specified according to the
results of test and examination certificates, and such loads must not be exceeded during
the lifting operation.

Repair and maintenance

All cranes shall have regular maintenance, to ensure they always kept in good operating
conditions.

6
 5.1.1 Mobile crane

Operation points:

• The mobile crane shall only be

operated on a firm, level
ground that adequately
supports the weight of the
crane and loads.

• Before lifting, fully extend

outriggers and ensure their
stability on the ground.

• The weight of the load shall not

exceed the Safe Working
Load.
a. Level ground
• Never abruptly swing or stop Correct operation
the crane. radius.

Operation radius
• Loads shall not be dragged on
the ground.
b. Uphill position
The load moves toward
• Move the load at a safe speed the crane and reduces
- use low speeds within the operation radius that
several metres of the load's may cause the crane to
tip over backwards.
destination.
Decrease in
• Adjust the boom length to operation radius
ensure the crane is operating
within the extent of the safe c. Downhill position
The load moves away
operation radius.
from the crane and this
may overloads the
• When moving uphill or crane and cause the
downhill, the boom angle shall crane to tip over
b e a d j u s t e d t o t h e s a fe forwards.

working condition.
Increase in
Avoid working on a slope operation radius

7
 5.1.2 Tower crane

Operation points:

• Ensure that the automatic safe

load indicator is installed.

• Provide safe means of access

and egress.

• Ensure that the lifting routes do not collide with

any object.

• Lifting routes shall not come across any building

or pass over any person.

• Travel speed shall be as slow as possible, to ensure

the load's stability.

• Be aware of the height of lifting, the length of the

crane's trolley and refer to the load chart.

• When the tower crane is not in operation, the crane's

trolley must be positioned near the tower at minimum
radius, with the hook raised to its highest position. Radiu
s
Load

• During typhoons, the jib shall be set to the

typhoon's leeward side with the brake released
allowing the jib to swing freely.

8
 5.2 Lifting gears
Lifting gears play an important part in the lifting operation. Their function is to tie the
objects tightly and hang them on the crane. There is a great variety of lifting gears. If there
is insufficient knowledge or a wrong choice is made, lifting may fail and accidents may
result. All lifting gears shall be tested by qualified examiners and suitably marked with a
Safe Working Load (SWL).

5.2.1 Wire rope slings

• Wire rope consists of individual wires laid into a
number of strands, which are then wrapped around
a central core.
Thimble
• Different number of wires in the strands and various Core
methods of arrangement may affect the
characteristics of the wire rope sling. The wire rope
shall be equipped with a thimble and with pressed
Strand
metal sleeve and marked with a Safe Working Load Wire rope sling
(SWL).
Wire

Inspection points:
• The wire rope sling shall not be used and shall be disposed if they are:

Broken wires Bird cages Kinks

Normal Normal diameter Reduced diameter Abnormal

Surface wires are worn Change of diameter of wire rope sling

by 1/3 or more

Points for attention:

• Use only suitable wire rope slings. • Sudden elevation is not allowed
• Never use damaged wire rope slings. • If more than one wire rope sling is used
• During lifting, the Safe Working Load must in lifting, pay attention to the angle
not be exceeded. between the slings.

• Regular inspections shall be conducted

9
 5.2.2 Wire rope slings - cable clip
The cable clip shall be properly installed according to the following points:

• The wire rope sling is equipped with thimble.

• There is a minimum of 3 cable clips. Thimble

• The direction of installation

shall be correct.

• The distance between the cable clips

shall be the same.

Method of connecting the wire rope slings:

10
 5.2.3 Chain slings
Chain slings are made up of chain rings. The advantage of chain slings is that they dete-
riorate and corrode less. Chain slings are made of alloys. They can maintain their Safe
Working Loads under temperatures of 50oF. However, the entire chain becomes unsafe if
problems arise in any section. A damaged chain sling will suddenly break and the damage
is not as easily detectable as compared to rope slings. Therefore, a rope sling must be
selected wherever possible for lifting.

Inspection points:
• The chain sling shall be not be used under the following conditions:

Stretched Bend Cuts, cracks Wear

Extreme wear at
bearing surfaces

Points for attention:

• No ordinary chains shall be used for lifting.

• The Safe Working Load (SWL) shall not be exceeded.

• No knots or bolts that shorten the chain length shall be used.

• Chain slings have no flexibility, so striking objects must be

avoided while lifting.

• Do not use hammers to reshape a deformed chain sling.

• When purchasing chain slings, those marked "A" should be

selected as they are of premium for normal use.

• Regular inspections shall be conducted.

11
 5.2.4 Shackles
Hook rings are divided into two main categories: Chain ("D" type) shackle and anchor
(bow) type shackle. Both are available with screw pins or round pins.

Check for wear

Check for wear

Anchor shackle and straightness

Check that pin is

always seated

Check that shackle

Chain shackle is not "opening up"

Points for attention:

• Never replace the shackle pin with a bolt. • Shackle pins must always be attached
to the hook.
• Ensure the pin is totally locked.
• Washers may be used to centre the
• Do not use screw pin shackles if the pin
shackle.
can roll and unscrew.

• During lifting, shackles shall not lean to

one side.

Washer Hook

If the load shifts, the sling

will unscrew the shackle pin

12
 5.2.5 Eye bolts
Eye bolts are mainly classified into plain (shoulderless) eye bolts and shoulder type eye
bolts.

• The bolt length shall be

1-1.5 times the diameter
of the bolt and totally
drilled on the load.

• The bolt hole shall fit

into the bolt

>45

Safety points:
• The hook shall not be directly fixed on to the
eye bolt.

• Plain eye bolts only apply to the vertical lifting.

• The angle of lifting of shoulder eye bolts shall
o
not be less than 45 .

• Washers may be used to ensure that the

shoulder is firmly in contact with the surface. Washers
• Never use a sling through a pair of eye bolts.

13
 5.2.6 Hooks
Hooks are a vital part of lifting gear. A variety of them cater for different lifting purposes.

Check for wear

and deformation
Check for signs of
"opening up"
Check for cracks
and twisting

Check for wear

and cracks

• All hooks shall be installed with safety latches

(other than the specially designed hooks).

• Hooks can be installed with swivels

to allow the load to revolve.

Points for attention:

• Select hooks of the right size.
• Do not tie or remove the safety latches.
• Maintain the hook in a vertical position. If the hook is eccentrically loaded, the Safe
Working Load will be reduced.

Center Center Center Center Center

Load Load Load Load Load

Can carry 100% Can carry approx. Can carry approx. Can carry approx. Can carry approx.
of Rated Load 86% of Rated Load 80% of Rated Load 70% of Rated Load 40% of Rated Load

14
 5.2.7 Rings, links, swivels
• Most of the rings, links and swivels are
marked with Safe Working Loads
(SWL). If no SWL is marked, the SWL
tables shall be checked according to
their diameters.

5.2.8 Spreader beams

• Spreader beams are commonly

used for lifting long loads.

• The weight of spreader beams shall

be included as part of the lifting load.

• Each of the contacted points shall

not exceed the SWL.

5.2.9 Chain mesh slings and fibre slings

• These are used for lifting

special materials.

15
 6. Load
• Know the weight and shape of the
load.

• Loose loads shall be packed or

placed in suitable containers before
lifting.

• The containers must be structurally

sound and 4 slings must be used to
avoid inclining.
SWL
: 1
T
• The containers shall be examined
and marked with Safe Working
Loads (SWL).

• Pay attention to the load's centre of

gravity - ensure that it is kept directly
under the main hook.

• Corner pads shall be used for loads

with sharp edges.

• When lifting large or heavy loads,

wind and operator visibility must be
considered.

16
 7. Method
• Plan a suitable lifting route, to
avo i d c o l l i s i o n w i t h a ny
persons, objects or overhead
power lines.

• Do not drag loads.

• Move the loads as near to the

ground level as possible.

• Stop people from standing in

the lifting area.

• Do not ride on a load that is

being lifted.

• When the crane is in operation, it must

maintain a distance of at least 600 mm
from any barriers or buildings.

• When visibility is blocked, the signal man

shall render assistance.
minimum 600mm

• Lifting the load at a low speed so that

the sling tightens slowly and maintains
a balanced position.

17
 8. Environment
Safe lifting can be affected by rain, thunderstorms, strong winds, ground conditions and
overhead power lines.

Rains
• Rains creates wet and slippery ground, loose soil and landslides, etc. Depending on the
situation, the operator shall decide whether to continue working or not. When the soil is
loose and could cause danger to the crane's stability, lifting work must be stopped.

Thunderstorms
• During thunderstorms, stop lifting operations immediately.

Strong winds
• In strong winds, decrease the weight of the Safe
Working Load to improve safety. If the wind intensifies,
work must be stopped.

Ground situation
• Loose soil - use firmer, larger wooden planks to
distribute the load and reduce the weight on the
soil.

• When on a slope, adjust the outriggers to keep

the crane horizontal.

• If there are excavations near the lifting appliances

- strengthen excavations' supports.

Overhead power lines

6 metre
• Stay well clear of overhead power lines.
The safety margin must be the jib's
distance + 6 metres, or the distance
suggested by the electricity suppliers.

Instruction from the signalman

is required for safety operation
18
 ISBN 962-968-122-6

9 789629 681227
Copyright 2002 Occupational Safety & Health Council 11/02 (01)