Risk Assessment for Lifting Operations and Lifting Work Activities

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This risk assessment covers lifting operations and lifting work activities involving cranes, hoists, slinging, rigging, load handling, and associated manual handling tasks. It applies to planning, preparation, lifting, travel of suspended loads, landing, unhooking, and post-lift activities. The assessment includes routine and non-routine lifts, use of lifting accessories and rigging hardware, exclusion zone management, inspection and maintenance interfaces, and compliance-related controls associated with safe lifting systems of work. It also considers risks to workers, contractors, visitors, and members of the public who may be exposed to lifting activities. Exclusions: this assessment does not replace equipment-specific manufacturer instructions, engineered lift plans for critical or unusual lifts, or site-specific permits and statutory inspections; these must be completed separately where required.

2. Risk Assessment Methodology

A structured hazard identification and risk evaluation process has been used, based on a 5x5 risk matrix and the hierarchy of controls. Hazards were identified by considering the full lifting lifecycle, the way work is organized, the competence and experience of personnel, foreseeable abnormal conditions, public exposure, and the potential for equipment or load failure. Each hazard was assessed for initial likelihood and severity, then controlled using elimination, substitution, engineering controls, administrative controls, and PPE. Residual risk was then reassessed after controls were applied. Manual handling hazards were considered using load characteristics, frequency, posture, distance, and worker capability. Rigging and crane-related controls were informed by inspection, lift planning, exclusion zone, and competent person requirements.

3. Risk Matrix Reference

The following matrix is used to evaluate risk levels based on likelihood and severity:

		Likelihood
Rare	Unlikely	Possible	Likely	Almost Certain
Severity	Catastrophic	Low	Low	Low	Low	Medium
Major	Low	Low	Medium	Medium	High
Moderate	Low	Medium	Medium	High	High
Minor	Medium	Medium	High	High	Extreme
Negligible	Medium	High	High	Extreme	Extreme

4. Hazard Identification and Risk Evaluation

1. Manual lifting, carrying, pushing, pulling, or lowering of loads that are too heavy, bulky, awkward, or frequently handled.

Potential Consequences: Musculoskeletal injury, including strains and sprains to the back, shoulders, arms, and hands; fatigue; reduced concentration; dropped loads; and secondary injuries from loss of control.

Affected Persons: Workers performing manual handling tasks, nearby workers assisting with the lift, and any person in the load path.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Eliminate unnecessary manual handling by using mechanical lifting aids, cranes, hoists, pallet trucks, or other suitable equipment.
• Substitute heavy or awkward loads with smaller, pre-assembled, or more manageable units where practicable.
• Use engineering controls such as adjustable work heights, trolleys, lift tables, and mechanical aids to keep loads close to the body and reduce bending and twisting.
• Apply administrative controls including manual handling assessments, task rotation, lift limits, team lifts, and clear instructions on safe lifting technique.
• Provide PPE such as suitable gloves and slip-resistant footwear where required, while recognizing that PPE does not reduce the load itself.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

2. Incorrect load weight, centre of gravity, size, shape, or lifting configuration leading to unstable or unbalanced lifting.

Potential Consequences: Load swing, load shift, dropped load, rigging overload, equipment damage, struck-by injuries, and fatal crushing injuries.

Affected Persons: Riggers, crane operators, signalers, workers in the fall zone, and nearby personnel.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Eliminate lifting where the load cannot be positively identified, weighed, or stabilized before the lift.
• Substitute unsafe lifting methods with engineered lifting points, spreader beams, or purpose-designed lifting attachments where appropriate.
• Use engineering controls such as load-rated rigging, spreader bars, edge protection, and tag lines to maintain control and balance.
• Require an approved lift plan that identifies the load weight, centre of gravity, rigging arrangement, travel path, landing area, and communication method.
• Ensure only trained and qualified riggers select rigging based on manufacturer ratings and the characteristics of the load.
• Keep all personnel clear of the load path and use exclusion zones and spotters where needed.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	High

3. Rigging failure due to defective, overloaded, damaged, modified, or incorrectly selected slings, shackles, hooks, or lifting accessories.

Potential Consequences: Dropped loads, equipment failure, struck-by injuries, crushing injuries, property damage, and fatality.

Affected Persons: Riggers, crane operators, workers in the vicinity, and any person beneath or near the suspended load.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Eliminate use of damaged or unverified rigging equipment and remove defective items from service immediately.
• Substitute worn synthetic slings with more durable rigging where the task and load permit, such as wire rope or chain slings.
• Use engineering controls by selecting rigging with adequate working load limits, proper identification, and suitable edge protection.
• Implement pre-use and periodic inspections by a competent person, with defective equipment tagged and removed from service.
• Prohibit field modification such as welding, drilling, knotting, splicing, or unauthorized repairs to rigging components.
• Require rigging to be selected, attached, and used in accordance with manufacturer instructions and the lift plan.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	High

4. Workers entering the fall zone, swing radius, or area beneath a suspended load during hoisting, landing, hooking, unhooking, or guiding activities.

Potential Consequences: Struck-by injuries, crushing injuries, entrapment, fatality, and panic-related unsafe movement during an emergency.

Affected Persons: Riggers, signalers, crane operators, other workers, visitors, contractors, and members of the public.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Catastrophic	Extreme

Control Measures

• Eliminate exposure by planning lifts so no person is required to work under or within the fall zone of the load.
• Use engineering controls such as barricades, physical exclusion zones, and clearly marked swing-radius boundaries.
• Apply administrative controls including a designated signaler, one-way communication, pre-lift briefing, and controlled access to the lift area.
• Restrict entry to only those workers essential to hooking, unhooking, guiding, or initial attachment tasks, and only when the task cannot be done from outside the fall zone.
• Require workers to keep hands, feet, and body parts clear of pinch points and to never walk under a suspended load.
• Provide high-visibility PPE and task-appropriate gloves where needed.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	High

5. Crane, hoist, or lifting equipment contact with overhead power lines or other electrical sources.

Potential Consequences: Electrocution, arc flash, burns, fire, equipment damage, and multiple-fatality incidents if the load or equipment becomes energized.

Affected Persons: Crane operators, riggers, signalers, nearby workers, and any person who may touch the load or equipment.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Eliminate the hazard by relocating the lift or de-energizing and grounding the power line where practicable before work begins.
• Use engineering controls such as range limit devices, warning lines, proximity alarms, insulating links where appropriate, and nonconductive tag lines.
• Establish and enforce minimum approach distances and a clearly defined work zone before the lift starts.
• Conduct a pre-lift planning meeting to identify power lines, obstructions, and control methods, and ensure the plan is communicated to all involved workers.
• Use a dedicated spotter or signaler with continuous communication to the operator when encroachment risk exists.
• Stop work immediately if conditions change or clearance cannot be maintained.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Catastrophic	High

6. Crane, hoist, or lifting equipment malfunction, including brake failure, limit switch failure, control failure, or overload.

Potential Consequences: Dropped or uncontrolled loads, collision, equipment collapse, struck-by injuries, and serious property damage.

Affected Persons: Operators, riggers, maintenance personnel, and workers in the vicinity of the equipment.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Eliminate use of equipment that is known to be defective or has unresolved safety-critical faults.
• Use only equipment that is suitable for the task and within rated capacity.
• Apply engineering controls through functional brakes, limit devices, overload protection, and manufacturer-approved safety systems.
• Perform pre-operation, shift, and periodic inspections by a competent person, with defects reported and corrected before use.
• Follow lockout/tagout or equivalent isolation procedures during maintenance and repair.
• Do not exceed rated load capacity or operate equipment with defective cables, controls, or limit switches.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	High

7. Poor communication, unclear signals, obstructed visibility, or inadequate lift direction during crane and hoist operations.

Potential Consequences: Unexpected load movement, collision, dropped load, struck-by injury, and confusion during abnormal events.

Affected Persons: Crane operators, signalers, riggers, nearby workers, and visitors.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Major	High

Control Measures

• Eliminate ambiguity by assigning one designated signaler for the lift, except for stop signals.
• Use standard hand signals or agreed radio communication methods that are understood by all involved personnel.
• Provide a lift plan and pre-job briefing covering roles, signals, travel path, landing area, and emergency stop arrangements.
• Use a spotter or signaler where the operator’s view is obstructed or where the load path is complex.
• Suspend lifting if communication is lost, visibility is inadequate, or instructions are unclear.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

8. Manual handling strain and ergonomic injury during slinging, guiding, landing, or repositioning loads, especially where awkward postures, twisting, or repetitive handling are required.

Potential Consequences: Musculoskeletal disorders, hand and finger injuries, reduced grip strength, fatigue, and delayed onset injury that may worsen over time.

Affected Persons: Riggers, slingers, laborers, and workers assisting with load positioning.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Eliminate unnecessary manual repositioning by using mechanical aids, better landing arrangements, or improved staging.
• Substitute awkward handling methods with tools such as tag lines, push poles, or lifting attachments that reduce direct contact.
• Use engineering controls such as stable landing surfaces, adjustable staging, and load supports to reduce holding and guiding effort.
• Apply administrative controls including task rotation, lift planning, weight verification, and limits on repetitive handling.
• Train workers to recognize early signs of musculoskeletal injury and to report symptoms promptly.
• Provide gloves and footwear suitable for the task and surface conditions.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

5. General Control Measures

• Implement a site-specific safe system of work for all lifting operations.

The system should define roles, lift planning requirements, communication methods, exclusion zones, inspection steps, and stop-work authority for unsafe conditions.

• Use only competent, trained, and authorized personnel for lifting-related duties.

Operators, riggers, signalers, and lift supervisors should be competent for the specific equipment and task, and workers should not be assigned duties beyond their training or experience.

• Maintain effective exclusion zones and access control around lifting operations.

Barricade the area beneath and around suspended loads, control public access points, and prevent unauthorized entry into the fall zone or swing radius.

• Ensure lifting equipment, accessories, and attachments are inspected and maintained.

Carry out pre-use checks, shift inspections, and periodic inspections by a competent person; remove defective items from service immediately and record corrective actions.

• Plan for abnormal and changing conditions before work starts.

Consider weather, poor lighting, night work, congested areas, simultaneous operations, lone work, and emergency access when planning the lift and selecting controls.

6. Emergency Preparedness

• Establish and communicate an immediate stop-work procedure for uncontrolled load movement, equipment malfunction, loss of communication, or unexpected entry into the exclusion zone. All workers must know how to signal a stop and move to a safe location.
• Prepare a rescue and response plan for dropped loads, trapped persons, struck-by incidents, and electrical contact. The plan should identify emergency contacts, access routes, first aid resources, and the actions to take if a load becomes unstable or energized.
• If a load contacts a power line, keep all personnel clear, do not touch the equipment or load, and wait for the utility authority or emergency responders to confirm the area is safe before any recovery attempt.
• Provide clear arrangements for isolating the area, accounting for personnel, and preserving the scene after a serious incident so that rescue and investigation can proceed without additional exposure.
• Ensure emergency equipment such as radios, first aid kits, fire extinguishers, and site access for responders are available and checked before lifting begins.

7. Training Requirements

• Crane, Hoist, and Lift Planning Training: Workers involved in lifting operations must be trained in lift planning, load identification, communication methods, exclusion zone requirements, and the limits of the equipment being used. Training should emphasize the importance of following the approved lift plan and stopping work when conditions change.
  • Load weight and centre of gravity
  • Travel path and landing area control
  • Roles of operator, rigger, signaler, and lift supervisor
  • Stop-work authority and escalation procedures
• Rigging and Slinging Competency Training: Riggers and slingers must be trained to select, inspect, attach, and use rigging equipment correctly. Training should cover sling types, working load limits, edge protection, hitch selection, tag line use, and the hazards of pinch points and load instability.
  • Inspection of slings, shackles, hooks, and attachments
  • Safe attachment methods and load balance
  • Defect recognition and removal from service
  • Avoiding knots, twists, splices, and unauthorized modifications
• Manual Handling and Ergonomics Training: Workers who manually handle loads must be trained to recognize ergonomic risk factors and use safer handling methods. Training should include load assessment, team lifting, use of mechanical aids, posture control, and early reporting of musculoskeletal symptoms.
  • Weight, size, shape, frequency, and handling method
  • Safe lifting posture and avoiding twisting
  • Use of mechanical aids and altered work procedures
  • Early signs and symptoms of musculoskeletal injury
• Electrical Hazard Awareness Training: Personnel involved in crane and hoist operations must be trained to recognize overhead power line hazards, minimum approach distances, and the actions required if equipment approaches or contacts an energized source.
  • Power line identification during site planning
  • Use of spotters, warning devices, and nonconductive tag lines
  • Emergency actions for electrical contact
  • Work stoppage when clearance cannot be maintained
• Inspection and Competent Person Training: Supervisors and competent persons must be trained to conduct and document pre-use, shift, and periodic inspections of cranes, hoists, and rigging equipment. Training should include defect recognition, removal from service criteria, and reporting requirements.
  • Inspection frequency and documentation
  • Criteria for defective equipment
  • Maintenance reporting and corrective action tracking
  • Manufacturer instructions and site procedures

8. Monitoring and Review

Review Frequency: Annually, and immediately after any incident, near miss, significant change in equipment, work method, personnel competence, or site conditions.

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Before each use and at the start of each shift	Competent person / equipment operator	Inspect cranes, hoists, slings, hooks, shackles, attachments, controls, brakes, and visible structural components for defects, damage, missing identification, or unsafe conditions. Remove defective equipment from service immediately.
Lift Plan Verification	Before each planned lift and whenever the lift changes	Lift supervisor / qualified rigger	Verify that the lift plan matches the actual load, rigging arrangement, travel path, exclusion zone, communication method, and environmental conditions. Reassess if the load, route, or site conditions change.
Exclusion Zone Compliance Check	Continuous during lifting operations	Supervisor / designated spotter	Monitor the fall zone, swing radius, and public access points to ensure no unauthorized person enters the controlled area. Stop the lift if the zone cannot be maintained.
Competency and Training Review	Annually and after any incident or significant change	Supervisor / safety manager	Confirm that operators, riggers, signalers, and competent persons remain trained and authorized for the equipment and tasks assigned. Refresh training where gaps, unsafe practices, or new hazards are identified.
Incident and Near-Miss Review	After every incident, near miss, or equipment defect trend	Management / safety representative	Review dropped-load events, rigging defects, communication failures, manual handling injuries, and electrical hazard exposures to identify root causes and implement corrective actions.

9. Special Circumstances

• Adverse weather such as high winds, rain, ice, snow, lightning, or poor visibility can increase load swing, reduce footing, and affect crane stability and communication. Lifting should be postponed or additional controls applied when conditions are unsafe.
• Night work or low-light conditions increase the risk of miscommunication, poor load visibility, and exclusion zone breaches. Additional lighting, supervision, and communication controls are required.
• Lone work or reduced staffing increases the severity of an incident because immediate assistance may not be available. Lifting tasks should be avoided where possible or supported by enhanced communication and emergency arrangements.
• Congested sites, public interfaces, and simultaneous operations increase the likelihood of struck-by incidents and access control failures. Coordination with other contractors and public protection measures are essential.
• New, inexperienced, or physically limited workers may face higher manual handling and rigging risk. Tasks should be matched to competence and capability, with closer supervision and additional controls where needed.

Approval and Sign-off

This risk assessment has been reviewed and approved by:

Assessor: _________________________ Date: __________

Manager/Supervisor: _________________________ Date: __________

Safety Representative: _________________________ Date: __________

This risk assessment must be reviewed annually, and immediately after any incident, near miss, significant change in equipment, work method, personnel competence, or site conditions. or when significant changes occur.

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