Safe Lifting UK

All lifts must be planned by a competent Appointed Person. This app is a reference tool — not a substitute for a formal Lift Plan.

PUWER

1998

Work Equipment
Regulations

BS7121

HSE Guidance

Safe Use of
Cranes & Signals

LOLER

1998

Lifting Operations
Regulations

Quick Reference

Appointed Person

Plans every lift, selects equipment, calculates loads and sling tensions, ensures LOLER compliance. Must be competent and independent of commercial pressure.

LOLER Examinations

Lifting accessories — every 6 months. Lifting equipment (cranes, hoists) — every 12 months. Records must be retained and available for inspection at all times.

Key Terminology

WLLWorking Load Limit

SWLSafe Working Load

APAppointed Person

CoGCentre of Gravity

RCIRated Capacity Indicator

ASLIAutomatic Safe Load Indicator

Privacy Policy

Slings — Technical Guide

Chain Sling

The toughest sling on site. Built for heavy, hot, rough, or abrasive loads. Alloy steel links with pear master link and clevis hooks.

Grade 8 / Grade 10LOLER 6-month exam

4:1

Safety Factor

–40° to 200°C

Temp Range

G8 / G10

Grade Stamp

Use When…

Heavy, rough, or abrasive loads

High-temperature environments

Steel, castings, or fabrications

Repetitive short-distance lifts

Do NOT Use When…

Polished or sensitive load surfaces

Temperature exceeds 200°C

Grade stamp missing or unreadable

Any link cracked, bent, or stretched

Step-by-Step — How to Use

1

Inspect every link — lay the chain flat. Check each link for cracks, nicks, gouges, bending, or twisting. Confirm grade stamp is present and readable.

2

Check the ID tag — every chain sling must show WLL, grade, length, and number of legs. No tag = remove from service immediately.

3

Select correct number of legs — 1-leg for vertical lifts, 2-leg or 4-leg for balanced loads. Confirm in the lift plan before rigging.

4

Attach to load lift points — hook each leg through designated attachment points in the approved hitch configuration. Never use a knot.

5

Master link to crane hook — seat fully in the bowl. Engage the safety latch. Confirm before signalling hoist.

6

Take up slack slowly — hoist until all legs are taut. Check balance. Lower and re-rig if the load tilts.

7

Store on a sling rack — never throw, drop, or drag chain slings. Impact causes invisible internal damage.

Discard Criteria

Any crack, nick, or gouge in any link — even hairline cracks cause sudden failure under load

Links bent, twisted, stretched, or opening — WLL has been exceeded

Wear exceeding 10% of original link diameter — measure with a calibrated gauge

Blue or yellow heat discolouration — chain has been overheated internally

Missing, illegible, or damaged identification tag

LOLER: Chain slings must be examined by a competent person every 6 months. Written examination report must be retained on file.

Wire Rope Sling

The industry all-rounder. Strong, flexible, and versatile — the most common sling on UK construction and industrial sites.

6×19 / 6×37 Construction

5:1 – 6:1

Safety Factor

Steel / Fibre

Core Type

To +100°C

Max Temp

Use When…

General construction and industrial lifting

Loads with rough or unfinished surfaces

Repetitive production lifting operations

Wet or oily working environments

Do NOT Use When…

Polished or easily marked surfaces

Sharp edges without corner protection

Broken wires visible anywhere on rope

Any kink, crush, or birdcage present

Step-by-Step — How to Use

1

Full-length inspection — uncoil and run your hand along the rope. Feel for broken wires, flat spots, kinks, and corrosion. Inspect ferrules at both eyes.

2

Check ferrules and eyes — swaged ferrule must be intact. Eye loops must not be stretched, deformed, or show wires pulled from the ferrule.

3

Identify all sharp edges on the load — fit corner/edge protectors before rigging anywhere the sling will contact a sharp edge.

4

Rig in the correct configuration — straight, basket, or choke per the lift plan. Do not change hitch on site without AP approval.

5

Seat eyes correctly on hook — eye must seat fully in the bowl of the hook, not balance on the tip. Engage safety latch.

6

Check sling angles before full hoist — both legs must be at least 30° from horizontal. Below 30° — stop and reposition.

7

Store hanging on a rack — never drag across the ground or expose to heat, grinding sparks, or corrosive environments.

Discard Criteria

6 or more broken wires in any one rope lay length — immediate discard

Any kink — a kinked rope cannot be straightened safely. Discard immediately

Birdcaging (strands splayed outward) — rope has been shock-loaded

Corrosion pitting or discolouration throughout the rope length

Crushed or flattened section, or ferrule cracked or pulled from eye

Webbing Sling

The gentle option. Wide, flat polyester strap — protects delicate, polished, or finished surfaces. Must be inspected for cuts before every use.

Polyester PESDiscard if cut

7:1

Safety Factor

To +100°C

Max Temp

EN 1492-1

Standard

Use When…

Polished, painted, or soft load surfaces

Glass, aluminium profiles, pipework

Wide bearing area needed on load

Machinery or fabrications with finishes

Do NOT Use When…

Sharp edges — sling will be cut immediately

Hot loads or above 100°C

Contact with acids, alkalis, or bleach

Any cut, tear, or abrasion visible

Webbing Colour Code — EN 1492-1

● Violet1 tonne

● Green2 tonnes

● Yellow3 tonnes

● Grey4 tonnes

● Red5 tonnes

● Brown6 tonnes

● Blue8 tonnes

● Orange10 tonnes

Discard Criteria

Any cut, nick, or abrasion penetrating the outer jacket — no exceptions

Chemical staining — may be internally weakened even if exterior looks intact

Burns or heat marks from welding, grinding sparks, or direct heat contact

Broken or pulled stitching at the eye — the critical load-bearing point

Label missing or unreadable — WLL and EN compliance cannot be confirmed

Round Sling

High strength endless loop — polyester yarn core inside a protective sleeve. Compact, flexible, and kind to load surfaces. Ideal for cylindrical loads.

Polyester yarn coreEN 1492-2

7:1

Safety Factor

EN 1492-2

Standard

Colour Coded

By WLL

Use When…

High strength needed in a compact form

Cylindrical loads — pipe, bar, drums

Tight spaces where flat sling won't fit

Delicate surface protection needed

Do NOT Use When…

Sleeve has any cuts, holes, or abrasion

Inner yarn is visible through the sleeve

Exposed to heat, sparks, or chemicals

Colour label or ID tag is missing

Round Sling Colour Code — EN 1492-2

● Violet1 tonne

● Green2 tonnes

● Yellow3.2 tonnes

● Grey4 tonnes

● Red5 tonnes

● Brown8 tonnes

● Blue10 tonnes

● Orange>10 tonnes

WLL values are for straight hitch. Basket hitch doubles WLL. Choke hitch reduces WLL by 20%.

Discard Criteria

Any hole, cut, or abrasion through the outer protective sleeve

Inner yarn visible — sling has lost its protection. Out of service immediately

Hard, lumpy, or uneven feel inside — possible internal yarn damage from overload

Chemical contamination — acids or alkalis destroy polyester yarn invisibly

Hitch Configurations

A hitch is the method of attaching a sling to a load. The same sling in different hitch configurations gives different WLL values. The lift plan specifies the required configuration — never change it on site without AP approval.

Straight / Vertical

WLL = 100%

Sling hangs vertically. Maximum rated WLL. Attachment must be directly above load CoG.

Basket Hitch

WLL × 2 (at 90°)

Sling loops under the load, both eyes to hook. Doubles WLL but load can rotate.

Choke Hitch

WLL × 0.8 (−20%)

Sling passes through itself and tightens. Ideal for cylindrical loads. Never on sharp edges.

Critical Rules — All Hitches

!

Sling angles matter — as the angle from horizontal decreases, leg load increases. Below 60°: caution. Below 30°: stop the lift — do not proceed.

!

Never change configuration on site — changing hitch type completely changes the WLL. AP approval required before any configuration change.

!

Test lift at 150mm — raise to 150mm and hold. Check balance, sling position, and load stability before continuing to height. Mandatory per BS 7121.

!

Choke hitch on edges — never apply a choke hitch over any sharp edge, protrusion, or weld bead. A sharp edge will cut the sling instantly under load.

Sling Angle Calculator

Angle from horizontal

60°

Load weight (tonnes)

10t

Acceptable — proceed with care

2-leg lift, 10t load at 60°

5.77t

Angle	Load Factor	Leg tension (10t)	Status
90°	1.000	5.00t	Ideal
75°	1.035	5.18t	Good
60°	1.155	5.77t	Acceptable
45°	1.414	7.07t	Caution
30°	2.000	10.00t	High load
20°	2.924	14.62t	Dangerous

NEVER rig below 30° from horizontal. At 30° the leg tension equals the full gross load weight.

Lifting Accessories

Bow Shackle

For multi-directional and angular loads. D-shaped bow allows multiple sling eyes. Pin must be fully closed and moused.

WLL: 0.5t – 120t

Dee Shackle

In-line loads only. Narrow profile — do not use for angular pulls or multiple sling legs. Pin must be fully secured.

WLL: 0.33t – 85t

Safety Hook

Spring-loaded safety latch prevents accidental disengagement. Latch must always be fully engaged before the lift commences.

WLL: 0.25t – 100t

Eye Bolt

Shoulder type for angular loads. Plain eye bolt for in-line only. Shoulder collar must be fully seated against the load surface.

WLL: 0.1t – 25t

Beam Clamp

Attaches to structural steel flanges. Match clamp WLL to flange thickness and width. Load must be applied vertically.

WLL: 0.5t – 10t

Swivel Hoist Ring

360° rotation and articulation. Ideal for off-centre CoG and angled picks. Must be torqued to manufacturer specification.

WLL: 0.25t – 32t

Plate Clamp

Self-locking on flat plate edges. Vertical lift only unless horizontal type specified. Plate thickness must fall within rated range.

WLL: 0.5t – 32t

Spreader Beam

Converts inclined sling forces to vertical. Eliminates inward compressive force on the load. Must have a valid test certificate.

WLL: Rated per design

Pre-Use Inspection — Every Single Time

Deformation · cracks · corrosion · wear >10% of cross-section · illegible markings · missing or damaged pins · heat damage · chemical attack. Any defect found — remove from service immediately.

Lift Plan

Job Details

Date

Site / Location

Appointed Person

Slinger / Signaller

Load Details

Load description

Gross weight (kg)

Lift classification

Crane / Equipment

Minimum SWL Required (6:1 Safety Factor)

Enter gross load weight above

AP must verify all equipment WLL meets or exceeds this value.

Roles & Duties

Appointed Person

CPCS A61 · TAP001 or equivalent competence

Planning AuthorityLegal Duty Holder

1

Plan every lift — produce a written lift plan before any operation. Cover load weight, CoG, rigging method, crane radius, ground conditions, and exclusion zone.

2

Calculate loads and sling tensions — verify gross load including all rigging. Calculate leg tensions based on hitch configuration and sling angles at the correct safety factor.

3

Select and specify all lifting equipment — confirm all items hold valid LOLER examination certificates with adequate WLL for the planned lift.

4

Assess all site conditions — inspect ground bearing capacity, crane access, overhead obstructions, underground services, and weather constraints.

5

Classify the lift — determine whether routine, complex, critical, or tandem. Governs planning depth, personnel required, and supervision level.

6

Brief all personnel — confirm each person understands their role, hazards, communication method, abort signal, and emergency procedures.

7

Sign off and retain records — sign the lift plan as the competent AP. All documentation retained for inspection by the HSE or LOLER enforcing authority.

8

Remain independent — not subject to programme or financial pressure. Has absolute authority to suspend or cancel any lift considered unsafe.

Crane Supervisor

CPCS A60 — covers on-site Lift Supervision duties

On-site ControlComplex & Critical

1

Confirm crane setup — verify crane is positioned per the lift plan. Outriggers fully extended, pads on firm ground, crane level within manufacturer's tolerances.

2

Verify capacity at the required radius — check the load chart. Confirm gross load is within rated capacity. Never exceed 90% of chart capacity without specific AP approval.

3

Liaise directly with the AP — confirm the lift plan is fully understood. Report any deviation before operations begin.

4

Brief the lift team — deliver the pre-lift toolbox talk. Confirm each team member understands their role, communication method, and abort procedure.

5

Coordinate all disciplines — direct the crane operator, slingers, and banksman. Only one authorised signaller communicates with the operator at any time.

6

Inspect all lifting accessories before use — confirm slings, shackles, hooks, and rigging gear are in-date, correctly rated, and undamaged.

7

Monitor the lift throughout — watch for load swing, wind, bystander intrusion, or unexpected load behaviour. Ready to call an immediate stop.

8

Immediate authority to stop the lift — can suspend operations at any point for any safety reason without requiring prior AP approval.

Crane Operator

CPCS A02 (mobile) · A04 (tower) · NPORS N108

Machine ControlCertified Only

1

Complete pre-use inspection — carry out the manufacturer's daily checklist before operation. Record all findings. Report any defect before beginning lifting.

2

Operate strictly within the load chart — never exceed the crane's rated capacity at the working radius. If load weight is uncertain, do not lift without written confirmation from the AP.

3

Accept signals from one designated signaller only — if signals are unclear or stop unexpectedly — stop and hold the load until clarified.

4

Maintain smooth load control — slow, controlled movements. Never slew a load over personnel.

5

Monitor the RCI/ASLI at all times — do not silence, bypass, or override any load warning system without explicit instruction from the Crane Supervisor and AP.

6

Report unusual behaviour immediately — lower the load safely before any investigation of unusual noise or movement.

7

Never leave the cab with a load suspended — remain at the controls at all times while a load is attached and off the ground.

Slinger / Signaller

CPCS A40 · NPORS N009 · BS 7121 hand signals

Load AttachmentSignalling

1

Inspect all accessories before every use — visually check every sling, shackle, hook, and rigging component. Remove any defective item from service immediately.

2

Attach the load in the specified configuration — rig slings exactly as specified in the lift plan. Protect slings at all sharp edges with corner protectors.

3

Confirm load is fully secure before signalling — all shackle pins tightened and moused. Hook safety latches engaged. Load visually balanced.

4

Give clear BS 7121 standard signals only — use only the standard code or agreed radio method. Never improvise. Only one slinger gives signals at any time.

5

Manage taglines safely — never wrap taglines around hands, wrists, or any body part. Release before the load rises beyond safe reach.

6

Control the exclusion zone — challenge any person attempting to enter beneath or adjacent to the load path. Call an immediate stop if the zone is breached.

7

Control landing and detachment — confirm load fully set on adequate supports before releasing slings. Never stand beneath a suspended load.

8

Emergency stop authority — give the emergency stop signal immediately the instant any unsafe condition is observed. This authority overrides all other instructions.

Banksman

CPCS A31 (recommended) · Site induction minimum

Zone ControlTraffic Management

1

Establish and enforce the exclusion zone — set up physical barriers and signage before any crane movement begins. Control all access points.

2

Guide crane travel and positioning — direct the crane where the operator's vision is restricted by blind spots, tight access, or congestion.

3

Manage pedestrian and vehicle conflict — prevent vehicles and workers from entering the crane slew radius or load travel path.

4

Relay signals where required — where the slinger cannot be seen by the crane operator. Only one person gives instructions to the operator at any time.

5

Monitor overhead hazards — maintain awareness of power lines, structures, and other cranes in proximity. Alert the Crane Supervisor to any potential conflict.

6

Immediate stop if zone is breached — give the emergency stop signal immediately if any person enters the exclusion zone without authorisation.

How Many Slingers?

Routine Lift

1

Slinger / Signaller

Single load, simple rigging, clear line of sight to operator throughout.

Long Load

2

One at each end

One slinger at each end. Only one gives crane signals. The other manages position.

Complex Lift

2+

Slingers minimum

Multiple attachment points or precision landing requiring simultaneous ground control.

Critical Lift

2+

Plus Crane Supervisor

Near capacity or hazardous load. AP must be present on site. Full team mandatory.

Tandem Lift

2+

One per crane min.

Each crane requires its own dedicated slinger. Radio comms mandatory throughout.

Blind / No Sight

2

Slinger + Banksman

Banksman relays signals where operator cannot see the slinger directly.

The AP determines the exact team composition during lift planning. Numbers above must never be reduced under commercial pressure.

Safe Lifting UK

Real UK site incidents — categorised, analysed, and mapped to regulation

109

Case Studies

7