A job for trained people
Moving a heavy machine is one of the more hazardous steps in installing equipment. A load that slips, tips or swings can injure people and wreck expensive equipment in seconds. This article gives a general overview of how such lifts are approached. It is not instruction for carrying one out. Rigging should be done only by trained, qualified and authorized people, using suitable certified equipment, following the equipment manufacturer’s instructions, the site’s rules and local regulations.
Equipment rigging covers the selection and attachment of slings, shackles, spreader beams, hooks and other hardware that connect a load to a lifting device, plus the planning of how the load is raised, moved and placed. Moving can also mean skidding, rolling or jacking, which have their own risks.
Why planning comes first
Most serious incidents in lifting are traced to something that was not known or not checked: an unknown weight, an unsuitable sling angle, a floor that could not carry the equipment, a missing lifting point, an unclear signal. A written lift plan is how a team tries to find these things beforehand. For routine, repeated lifts, plans may be standard; for unusual or heavy items, a specific plan is usually prepared, and in some cases reviewed by an engineer.
A plan generally addresses:
- The load: its actual weight, dimensions, center of gravity and any fragile or sensitive parts
- The route: where it is lifted from, the path it takes and where it is set down
- The equipment: the cranes, hoists, forklifts, jacks, skates or gantries to be used, and their rated capacities
- The rigging: slings, shackles and attachments suited to the load and the angles involved
- The people: who is in charge, who is rigging, who signals, who operates, and who keeps others clear
- The site: ground or floor strength, overhead obstructions, power lines, wind or weather if outdoors, and exclusion zones
- Contingencies: what to do if something changes or goes wrong, and how to stop the job
Finding out the weight and lifting points
Do not guess a weight. The manufacturer’s documentation typically states the shipping weight and may mark the heavy parts separately. Lifting points are designed into many machines, such as eyebolts, lugs or dedicated lifting holes, and the manual usually shows how they should be used, including the required sling arrangement. Using the wrong points can bend frames, damage components or make the load unstable. If weight or lifting points are unclear, the right step is to ask the manufacturer or an engineer, not to improvise.
Center of gravity matters because a load hung from the wrong position tilts when lifted. Machines with heavy motors on one side, or with removable counterweights, are often off-center. Packing lists and drawings may mark it. Unbalanced components that can shift during a lift, such as loose carriages or fluid in a vessel, should be secured or removed.
Equipment and ratings
Lifting equipment has rated capacities, and these ratings depend on conditions. A sling’s capacity changes with the angle at which it is used, and a crane’s capacity changes with reach. Qualified riggers and operators work with load charts and manufacturer data to keep loads within limits, usually with a margin. Equipment should be inspected before use and removed from service if damaged. Lifting gear is typically tagged, marked with its rating and subject to periodic examination under local rules.
Typical options for moving heavy machinery in plants include overhead cranes, mobile cranes, forklifts and heavy-duty trucks, gantry systems, jacks and skates. Each has strengths and limits. For example, forklifts have capacity that falls as the load center moves away from the forks, and overhead cranes rely on the building structure. The choice of overhead cranes, hoists or other devices depends on the load, the route and the site, and it is not a decision to be made casually.
The people involved
Roles are typically defined. A lift supervisor or competent person is responsible for the plan. Riggers attach and detach the load. The operator controls the lifting device. A signal person communicates, using standard hand signals or radios where the operator cannot see the load. Everyone knows who may give a stop signal, and anyone is generally expected to be able to call for a stop if they see danger.
Qualifications and certification requirements vary by region and equipment type, so a plant or contractor typically checks that their riggers and operators hold what local rules require.
Core safety habits
Without being a procedure, certain themes recur in safe lifting:
- keep people out from under or near suspended loads
- establish exclusion zones and keep them clear
- do a trial lift just clear of the ground, to check balance and rigging before going higher
- move slowly and avoid sudden starts, stops and swinging
- use taglines or other methods to control rotation, where appropriate
- do not exceed the rated capacity of any component
- stop the job if conditions change, such as wind, visibility, or an unexpected load behavior
- never use damaged or unmarked gear
Moving within a building
Indoor moves bring special concerns. Floor capacity may be limited, particularly on mezzanines, in basements or over services below. Doorways and corners may restrict size. Equipment such as air receivers, tanks and gearboxes can contain residual fluids or pressure that must be drained or released, using safe isolation practices, before anyone moves them. Floor protection, such as plates to spread loads and protect surfaces, may be needed. Collisions with piping, cable trays, sprinklers and lighting are common when routes are not checked beforehand.
Setting down
Placing the equipment is part of the lift. The base or foundation should be ready, and the machine lowered slowly and positioned within the allowed tolerance. Final leveling and anchoring follow the manufacturer’s instructions and are covered by how machine foundations are prepared. The rigging is only removed once the load is stable and supported.
Equipment protection in transit
Transport locks, shipping braces and covers are fitted for a reason, and they usually stay on until the manufacturer says to remove them. Delicate items, such as sensitive instruments or precision shafts, are commonly protected or removed for shipping. A visual check after the move, for damage, fluid leaks or shifted parts, is a sensible step before connection and start-up.
When in doubt
If a lift seems unusually heavy, awkward or poorly understood, the safe answer is to bring in specialist rigging contractors and, where required, engineering support. The cost is small compared with the cost of a dropped machine or an injury. This article is general information only and does not replace training, the manufacturer’s instructions or local regulations.