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Risk Assessment: Mechanical Handling - Lifting Operations

Document Information

Field Value
Document Reference RA11
Issue Number 2
Issue Date 1 June 2026
Next Review 1 June 2027
Prepared By Sean Ashton
Approved By Aaron Mason, Director

Risk Assessment Table

Activity/Process Hazard Who/What Affected Existing Controls Pre-Control Risk (S/L/R) New Controls Required Post-Control Risk (S/L/R)
All lifting operations using cranes, excavators or HIABs Failure of lifting equipment or accessories Site personnel, visitors and members of the public - Risk of crush injuries or fatalities if equipment fails • Lifting equipment and accessories selected with adequate strength and stability
• Equipment thoroughly examined (12 months for equipment, 6 monthly for lifting personnel/accessories)
• Equipment examined following significant incidents
• Lifting accessories stored in clean dry location
• All equipment inspected for defects before use
• Weekly inspections by competent person
• Adequate space for outriggers when using HIAB or crane		 5/2/10 (High) • Ensure inspection regime is adequately documented
• Consider digitising inspection records for better tracking
• Implement quarterly audits of lifting operations
Health & Safety Manager, within 3 months		 5/1/5 (Moderate)
All lifting operations using cranes, excavators or HIABs Being struck by the load, equipment or accessory Site personnel, visitors and members of the public - Risk of impact injuries or fatalities • All lifting operations planned by competent person
• All lifting carried out under supervision of competent banksman
• Personnel must have valid CPCS or NPORS card
• Personnel access to lifting areas restricted		 5/2/10 (High) • Implement documented lift plans for all complex lifts
• Enhance banksman training to include emergency scenarios
Site Supervisor, within 2 months		 5/1/5 (Moderate)
Lifting with excavators Misuse of plant Site personnel, visitors and members of the public - Risk of injury from plant tipping or load falling Excavators only used for lifting if they have:
• Suitable lifting eye that has been tested
• Safe working load (SWL) indicator in cab
• Fitted with check valves
• Lifting charts clearly displayed in cab
• All lifting subject to a lifting plan		 5/2/10 (High) • Implement spot checks of excavator lifting operations
• Enhance operator training on lifting with excavators
Operations Manager, within 1 month		 4/2/8 (Moderate)
Lifting operations near overhead services Contact with overhead services Site personnel, members of the public - Risk of electrocution or burns • Site survey prior to lifting operations
• Use of goal posts and exclusion zones
• Communication with utility providers where necessary
• See Overhead Services RA		 5/2/10 (High) • Ensure all banksmen receive specific training on overhead hazards
• Cross-reference with Method Statement - Safe Working in the Vicinity of Overhead Services
Leanne Mason, within 2 months		 5/1/5 (Moderate)
Slinging/attaching loads Incorrect slinging techniques causing load to become unstable or detach Site personnel, visitors - Risk of crush injuries if load falls • Only trained personnel undertake slinging operations
• Selection of appropriate lifting accessories
• Inspection of lifting points and load integrity
• Pre-lift checks of all lifting accessories		 4/2/8 (Moderate) • Additional training for slingers on complex load assessment
• Implement load assessment checklist for unusual loads
Leanne Mason, within 3 months		 4/1/4 (Low)
Manual handling associated with lifting operations Musculoskeletal injuries from handling lifting accessories Site personnel - Risk of back, arm or hand injuries • Manual handling training provided
• Team lifting for heavier accessories
• Storage arranged to minimise manual handling
• See Manual handling RA		 3/3/9 (Moderate) • Review storage arrangements for lifting accessories
• Provide mechanical aids where practical
Site Manager, within 2 months		 3/2/6 (Moderate)
Lifting in adverse weather conditions Equipment instability due to wind, rain or poor ground conditions Site personnel, visitors and members of the public - Risk of equipment failure or load dropping • Weather conditions assessed before lifting
• Maximum wind speeds specified in lift plans
• Ground assessment prior to setup
• Operations halted if conditions deteriorate		 5/2/10 (High) • Development of site-specific weather monitoring protocol
• Enhanced ground assessment training for supervisors
Health & Safety Manager, within 1 month		 4/2/8 (Moderate)
Tandem lifts with multiple lifting equipment Synchronisation failures between lifting equipment Site personnel, visitors - Risk of load instability, dropping or equipment damage • Specific tandem lift plans developed
• Enhanced communication protocols between operators
• Supervision by competent person
• Only experienced operators used		 5/2/10 (High) • Develop specific tandem lift procedure
• Implement simulator training for tandem lift scenarios
Leanne Mason, within 6 months		 5/1/5 (Moderate)
Lifting near excavations or unstable ground Ground failure causing equipment instability Site personnel, visitors - Risk of equipment tipping or overturning • Assessment of ground conditions before positioning
• Minimum safe distances from excavation edges
• Use of outrigger mats where necessary
• See Excavation RA		 5/2/10 (High) • Review and update ground bearing capacity assessment procedure
• Enhanced training on ground assessment
Technical Manager, within 2 months		 4/2/8 (Moderate)
Lifting and positioning pipes and fittings Crush injuries during positioning, swinging loads Site personnel - Risk of crush injuries to hands and feet • Taglines used to control load
• Exclusion zone established
• Communication protocols between banksman and operatives
• See Method Statement - Laying Mains		 4/3/12 (High) • Implement specific pipe handling procedure
• Enhanced training on pipe positioning techniques
Operations Manager, within 1 month		 4/2/8 (Moderate)

Key:

  • S = Severity (1-5 scale)
  • L = Likelihood (1-5 scale)
  • R = Risk Rating (S × L)
  • Risk Levels:
  • Low (1-3)
  • Moderate (4-8)
  • High (9-15)
  • Very High (16-25)
  • LOLER (Lifting Operations and Lifting Equipment Regulations) 1998
  • BS 7121: Code of Practice for Safe Use of Cranes