Every day across construction sites, warehouses, factories, workshops, hospitals, and ports, lifting equipment carries the weight of productivity. They help move heavy loads effectively and ease worker strain. However, these benefits come with serious risks when safety protocols are ignored or poorly implemented. Let's discuss all of this in this article.

What is lifting equipment?

Lifting equipment refers to tools, machinery, and accessories designed to safely raise, lower, move, or support loads. These are commonly used in construction, manufacturing, warehousing, transportation, and maintenance operations. Lifting equipment helps handle materials that cannot be moved manually.

Common types of lifting equipment

Here is some popular lifting equipment:

• Cranes: Cranes use wire ropes or chains with hooks to lift and move loads. Common examples include tower cranes, which are ideal for construction sites requiring high vertical reach, and mobile cranes for flexible lifting operations.
• Winches: Winches are pulling and lifting devices that use a rotating drum wound with a cable or rope. They are often used to move loads horizontally or on slopes and can support vertical lifting in specific applications.
• Slings: Slings are flexible lifting accessories made from wire rope, chain, or synthetic webbing. They wrap around or attach to loads and connect them to cranes or hoists.
• Forklifts: They are equipped with front forks and are widely used in warehouses, docks, and factories to handle palletised materials, load trucks, and organise storage racks.
• Hoists: They are compact lifting devices that raise or lower loads vertically using chains or wire ropes powered manually, electrically, or pneumatically. They are commonly mounted on overhead beams or gantry systems in factories and warehouses.

Major risks and hazards in lifting operations

Common risks in lifting operations include:

• Overloading: When lifting capacity is exceeded, components may fail or collapse, resulting in falling loads that can cause serious injuries or loss of life.
• Unstable ground conditions: Soft or uneven surfaces can cause cranes or lifting equipment to tilt or sink, resulting in loss of balance, tipping, or unintended load movement.
• Improper rigging: Incorrect slinging methods, wrong angle loading, or damaged rigging gear can cause load slippage, imbalance, or sudden release during lifting operations.
• Obstructed lifting path: Overhead structures, power lines, or nearby machinery can be struck by loads or booms, causing collisions, electrocution, or falling objects.

Essential safety guidelines for lifting equipment

Here are some safe mechanical lifting guidelines:

• Inspect all lifting equipment before use to identify wear, cracks, corrosion, or defects.
• Confirm that the load weight does not exceed the equipment’s rated capacity.
• Use only qualified operators trained in lifting procedures.
• Ensure loads are balanced, stable, and securely attached.
• Use appropriate slings, shackles, and attachments for the load type, shape, and weight.

Maintenance and inspection requirements

Here are some maintenance guidelines for lifting and manual handling:

• Lubricate all moving parts, including sheaves, bearings, and gears.
• Check the braking systems to confirm they engage properly.
• Verify the limit switches and safety cutoffs are functioning correctly.
• Clean equipment surfaces regularly to remove dust, grease, and debris.
• Replace worn or damaged components only with manufacturer-approved parts.

Role of insurance in lifting equipment safety

Depending on the insurer, you can get protection against mechanical failures, accidental damage, theft, and natural disasters. You can also consider buying a group personal accident insurance or employee’s compensation insurance, as this policy safeguards workers operating the machinery by providing financial support in the event of injury or death.

Employer’s responsibility and legal compliance

Employers are legally required to ensure lifting equipment is safe, certified, regularly inspected, and used only by trained personnel under the Occupational Safety, Health & Working Conditions (OSHWC) Code, 2020. Failure to comply with the law can lead to penalties, shutdown orders, or liability for workplace injuries.

Best practices for safe lifting operations

Here are some best practices to follow when conducting a lifting operation:

• Verify load weight and centre of gravity to prevent overloading equipment.
• Ensure operators and riggers are trained and authorised to handle lifting equipment, understand load charts, correct rigging methods, and follow emergency procedures.
• Establish clear communication using hand signals, radios, or a designated signalperson to avoid confusion.
• Barricade the lifting area to keep unauthorised personnel clear of suspended loads and potential drop zones.
• Follow the manufacturer's load charts strictly.

Conclusion

Workplace productivity depends on lifting equipment as well, yet improper use can result in accidents. Following strict maintenance, inspection, and operation protocols mitigates risks. When paired with comprehensive insurance and group personal accident coverage, both workers and assets are protected, promoting a safer, legally compliant, and efficient workplace culture.

FAQs

1. Which types of equipment fall under lifting safety rules?

Lifting safety rules apply to cranes, forklifts, chain hoists, electric hoists, gantries, stackers, pallet jacks, winches, lifting tables, and related lifting accessories.

2. Why is equipment inspection critical before lifting tasks?

Inspections identify wear, deformation, corrosion, cracks, loose bolts, electrical faults, and hydraulic leaks that can lead to sudden failures.

3. How are safe lifting loads determined?

Safe lifting loads are established through manufacturer specifications, load charts, equipment configuration, and site conditions.

Disclaimer: The information provided in this blog is for educational and informational purposes only. It may contain outdated data and information regarding the topic featured in the article. It is advised to verify the currency and relevance of the data and information before taking any major steps. ICICI Lombard is not liable for any inaccuracies or consequences resulting from the use of this outdated information.