Lifting equipment typically gets replaced because either it has failed an inspection, or it has failed in use. The first is a nuisance. The second is a completely different issue altogether.
This guide goes through all the different types of lifting equipment that you will find in an industrial or warehouse environment, shows you how they work and when they should be used, and shows you what you will need to do to keep in compliance with LOLER on a daily basis. If you are equipping a new facility, auditing your current equipment or just trying to make sense of what is available in the market, you are looking at the right guide.
Chain Hoists and Lever Hoists
Chain Hoists are the most commonly used lifting equipment in industry. A manual chain hoist (sometimes called a chain block) has a hand chain that drives a load chain through a reduction gear to generate a mechanical advantage, enabling the user to lift a load that would otherwise be impossible to move. Hoists are suspended from a fixed point or a beam trolley and are available in a range of lifting capacities from half a tonne to several tonnes, depending upon the model.
The primary distinction between chain hoists and lever hoists lies in their method of operation. Chain hoists facilitate vertical lifting with a hand chain that, when pulled, raises the hoisted load. Lever hoists, with their lever-operated ratchet mechanism, are more versatile for pulling, tensioning, and lifting from various angles. Lever hoists are optimal for positioning machinery, securing loads on a flatbed, and lifting in spaces with limited vertical clearance and access above the load.
Neither a lever hoist nor a chain hoist should be operated above their rated capacity, which is plainly marked on the devices. The rated Working Load Limit (WLL) signifies a boundary, and is not to be regarded as a limit that can be approached with care.
Electric Hoists
For lifting tasks that require a large number of repetitions over the same period of time, manual hoists become inefficient and negatively impact overall productivity. For an operation that requires continuous movement of materials or a fast-paced dispatch operation, manual hoists are impractical. Relying on electric hoists for these operations is more efficient as they operate without the manual effort and move loads faster.
In most general industrial applications, electric chain hoists are the predominant type of electric hoists. However, for applications that require the lifting of larger loads and higher elevations, and that are of a more demanding nature, wire rope hoists are more appropriate as they have greater mechanical strength. The constraints of these hoists are their greater size and cost.
Modern electric hoists typically come with overload protection, upper and lower limit switches, and motor thermal protection. These features are a requirement with LOLER (the Lifting Operations and Lifting Equipment Regulations, 1998). Hoists must be safe, and those without safety features are not safe.
Overhead and Gantry Cranes
An overhead or bridge crane consists of hoists that move along a bridge beam that is supported by vertical beams situated on the sides of the runway. These cranes cover the entire working space. For every business, such as fabricators, engineering workshops, and manufacturing, that needs to move heavy materials on a large scale, these cranes are the optimal choice.
Top running and bottom running cranes are differentiated by the location of the bridge beam with respect to the runway rail. For heavy loads and large industrial applications, top running cranes are preferred. For smaller loads and height restrictions, bottom running cranes are used.
A gantry crane is a bridge crane that is self-supporting. Whereas, in a fixed bridge crane, the support beams are a part of the building, the support legs of a gantry crane are a part of the crane itself. A good example of a portable gantry crane with a built-in lifting mechanism is in maintenance. It is impractical to install a fixed overhead crane for lifting operations.
Jib cranes have specific functions. These cranes have a wall or floor column attachment. They swing and cover localized lifting at a workstation. This could be a CNC machine or an assembly station. As overhead cranes cover an entire bay, jib cranes cover fixed points. Often, the two cranes are used together.
Lifting Accessories — Slings, Shackles, and Hooks
The crane and hoist form a part of a system. The load connection is as important as the lifting mechanism.
For industrial lifting, the best choice is a chain sling. The chain slings offer the best resistance to heat, abrasion, and chemicals. Chain slings are available as single, two-leg, three-leg, or four-leg slings. To maintain balance and to ensure the safe lifting of a load, the load should be attached to as many sling points as possible.
Textile slings are better when loads are valued and concern exists about the surface of the load being damaged. The steel chain would cause a load surface to become damaged. Especially if the load is glass.
Slings are connected to the hoist via a shackle. When a load can be pulled in many directions, bow or omega shackles are the best choice. For in-line pulls only, dee shackles can be used, but a dee shackle should not be used when the load is pulled in multiple directions. This is a common mistake and causes the shackle to exceed its rated capacity.
Each accessory includes a WLL, and each accessory in the lifting set must be rated to the weight of the load at a minimum. The system’s capacity is decided by the weakest link in the system — a 5-tonne chain sling and a 2-tonne shackle provide a 2-tonne lift.
LOLER — What It Actually Requires
The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) cover all lifting equipment employed in the workplace. The basic requirements state that:
Lifting equipment must be examined at defined intervals by a competent person — six months for equipment used to lift people, twelve months for other lifting equipment, or in any exceptional case (an accident, damage of a significant magnitude, a long period of disuse) that may have impacted the safety of the equipment.
Thorough examination and a simple visual inspection are two different things. A thorough examination is a detailed process carried out by a qualified engineer, who either approves the equipment for further use by issuing a report, or identifies the defects and repairs must be carried out within that reported timeframe.
LOLER mandates that every lifting operation is planned by a competent person, which means that person must understand the equipment and the load within the given environmental context.
The HSE issued guidance on LOLER compliance. It is important to read the regulations in their entirety and not rely solely on summaries. Employers are responsible for compliance. There are serious consequences for non-compliance, whether from enforcement action or through something more severe like an incident.
Selecting the Appropriate Equipment
There are four main factors to consider when selecting the correct lifting equipment: the load’s weight, the rate of use, the working environment, and the load’s movement.
Weight should be the first consideration, but the rate of use is also crucial. A 2-tonne chain hoist is sufficient when used for infrequent maintenance lifts, but when used 40 times a day in a production line, it will have a much shorter lifespan, will require more regular inspections, and is almost certainly the wrong tool for the job. An electric hoist with a beam trolley would be a more appropriate choice and would be faster and less fatiguing for the operator.
The working environment should also be taken into consideration. Equipment should be chosen based on whether it will be used outdoors, in the presence of chemicals, at elevated temperatures, and in the presence of explosive atmospheres. The availability of ATEX-rated hoists are a perfect example of why this is necessary. Standard electrical equipment in explosive atmospheres would create a significant safety concern.