Lifting & Rigging Operations Risk Assessment

Lifting & Rigging Operations Risk Assessment

Have you ever seen a crane lift a multi-ton beam or an industrial transformer? If yes, you’ve witnessed the sheer complexity and danger of lifting and rigging operations. A single error could cause property damage, personal injury, or even death.

That’s why a Lifting & Rigging Operations Risk Assessment is not just important—it’s mandatory for safe lifting tasks across construction, oil & gas, manufacturing, and maintenance projects.

Let’s break it down so that even your new rigging assistant can understand it.

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📜 Legal Standards & Safety Guidelines

Key Regulations

• OSHA 1926 Subpart H & CC – Lifting gear, cranes, hoists
• ANSI/ASME B30 Series – Rigging and lifting standards
• IS 816, IS 2762 (India) – Safety in crane and hoist operations
• LOLER (UK) – Lifting Operations and Lifting Equipment Regulations

Who Is Responsible?

• Employer – Provide safe equipment, training, and planning
• Rigger – Inspect slings, shackles, and follow signals
• Signalman – Maintain constant communication with operator
• Operator – Ensure safe movement and load stability

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⚠️ Common Hazards in Lifting and Rigging Operations

Hazard Type	Example
Dropped Load	Load detachment, snapping slings
Swinging Load	Side-sway due to wind or unbalanced lift
Equipment Failure	Broken hook, damaged shackle
Rigging Misuse	Wrong sling angle or hitching
Human Error	Miscommunication, poor signaling
Environmental	High wind, lightning, uneven ground

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🛠 Types of Lifting Equipment

Cranes

• Mobile Crane
• Tower Crane
• Crawler Crane
• Overhead Crane

Hoists & Lifting Gear

• Chain Blocks
• Lever Hoists
• Electric Hoists

Rigging Accessories

• Slings (Wire rope, synthetic)
• Shackles, Hooks, Eye Bolts
• Spreader Bars

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📋 Step-by-Step: Risk Assessment for Lifting & Rigging

1. Break Down the Task

What’s being lifted? Where and how?

Example: “Lifting a diesel generator (3T) onto the second floor with a mobile crane.”

2. Identify Hazards

At each step, ask: “What could go wrong?”

3. Assess the Risk Level

Use the 5×5 matrix to calculate Risk = Likelihood × Severity.

4. Apply Controls

Based on the hierarchy of control measures.

5. Monitor & Review

Update assessment if conditions change (e.g., wind picks up).

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📊 5×5 Risk Assessment Matrix

Severity \ Likelihood	Rare (1)	Unlikely (2)	Possible (3)	Likely (4)	Almost Certain (5)
Insignificant (1)	1	2	3	4	5
Minor (2)	2	4	6	8	10
Moderate (3)	3	6	9	12	15
Major (4)	4	8	12	16	20
Catastrophic (5)	5	10	15	20	25

• 1–3 (Green): Low – Acceptable
• 4–6 (Amber): Medium – Needs attention
• 7–15 (Red): High – Must control
• 16–25 (Dark Red): Extreme – Do not proceed

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📌 Sample Lifting & Rigging Risk Assessment Table

S.No	Task	Hazard	Risk (L×S)	Risk Level	Control Measures	Responsible
1	Slinging load	Incorrect sling angle	3×4 = 12	High	Use proper angle (30°–60°), apply load chart	Rigger
2	Lifting with mobile crane	Load swing	3×5 = 15	High	Use tag lines, stop work during wind >20 km/h	Signalman
3	Lifting near live cables	Electrocution	2×5 = 10	High	Isolate power, use spotters, follow minimum approach distance	Supervisor
4	Overhead load above workers	Dropped object	4×4 = 16	Extreme	Barricade area, avoid overhead lifting over people	Safety Lead
5	Using worn-out lifting gear	Equipment failure	3×5 = 15	High	Pre-use inspection, discard damaged slings/shackles	Rigger
6	Load positioning	Finger/foot pinch	2×4 = 8	Medium	Use hand-free zones, never stand between load and wall	All
7	Multi-crane lift	Load instability	4×5 = 20	Extreme	Appoint lift supervisor, prepare detailed lift plan	Lift Planner

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🔒 Control Measures for Safe Lifting Operations

Engineering Controls

• Certified lifting gears
• Anti-sway devices
• Load limiters on cranes

Administrative Controls

• Lift Plan & Permit to Lift
• Toolbox Talk before lifting
• Wind speed monitoring
• Designated signalmen

PPE Requirements

• Helmet with chin strap
• Steel toe boots
• High-visibility vest
• Leather gloves

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📐 Load Calculations and Planning

Things to Check:

• Load Weight (Tons)
• Center of Gravity
• Sling Angle (affects tension)
• Capacity of equipment
• Swing radius and nearby obstructions

Use the Crane Load Chart and Rigging Calculation Formulas to verify.

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📑 Pre-Lift Checklist

Before you lift:
✅ Crane setup on level ground
✅ Outriggers deployed
✅ Load balanced and slung properly
✅ Area barricaded
✅ Signalman appointed
✅ Radio check and communication confirmed
✅ Wind speed < 20 km/h

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🧠 Competency & Role of Personnel

• Rigger: Trained to inspect, select, and connect lifting gear.
• Signalman: Uses standard hand/radio signals.
• Crane Operator: Must be certified.
• Lift Supervisor: Required for non-routine/critical lifts.

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🧾 Permit to Lift / Lift Plan System

Required When:

• Load > 5 tons
• Lifting near critical infrastructure
• Multiple cranes used
• Working at night
• Close to public roads or live plants

Lift plan should include:

• Load details
• Crane specs
• Communication plan
• Sketch/diagram
• Emergency contact info

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🚨 Emergency and Rescue Preparedness

Always have a rescue plan in case of:

• Load collapse
• Trapped worker
• Contact with live wires

Conduct mock drills monthly and keep first-aid kits and stretchers available.

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✅ Benefits of a Proper Risk Assessment

• Prevents equipment damage and injury
• Reduces downtime
• Builds confidence in team
• Improves compliance with legal bodies
• Enhances safety culture

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🧭 Conclusion

Lifting operations can be predictable or disastrous—the difference lies in your planning and risk assessment. Don’t leave safety up to luck. Identify hazards, evaluate risk, control it, and always be prepared for the unexpected.

You don’t get a second chance when you’re handling 10-ton loads suspended mid-air.

Electrical Work Risk Assessment

Hot Work Risk Assessment

Confined Space Entry Risk Assessment

Working at Height Risk Assessment

Chemical Processing Risk Assessment

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❓FAQs

1. What’s the minimum requirement to be a rigger?

Typically, formal rigging training and third-party certification is required. In India, it may include NSDC/BOCW-accredited training.

2. Do you need a permit for every lift?

Not for all. But non-routine and critical lifts (like tandem lifts, heavy loads, or near utilities) always need a permit to lift and detailed lift plan.

3. How often should rigging gear be inspected?

• Before every use (visually by rigger)
• Monthly/Quarterly (by certified inspector)
• Annually (for re-certification)

4. Who approves the lifting plan?

Usually the site engineer or safety officer, depending on your organization’s hierarchy and policy.

5. Can I use web slings for hot jobs?

No. Use chain slings or wire rope for high-temperature jobs. Web slings can melt or lose strength.