Procedure for Safe and Proper Operation of Lifting Equipment

In manufacturing, logistics, or construction environments, lifting equipment is the tool that helps businesses optimise productivity, reduce manual labour, and handle loads far beyond human capabilities. However, high efficiency is always accompanied by significant safety risks if the equipment is not operated in accordance with proper procedures.

Reality shows that the majority of incidents involving overhead cranes, forklifts, hoists, or assistive lifting devices do not stem from machine failure but from ignoring or misunderstanding operating procedures. Just one incorrect operation—such as off-centre lifting, exceeding the load limit, or failing to check equipment before a shift—can lead to serious accidents, causing loss of life, property damage, and production interruptions.

Therefore, building and adhering to a standard lifting equipment operating procedure is not only a mandatory requirement under occupational safety regulations but also the foundation for stable and sustainable business operations. For Vietmani, safety is not just a slogan; it is a system of standardised procedures, training, and daily practice.

In this article, Vietmani will take you from core safety principles and necessary technical grounds to a clear, easy-to-apply step-by-step operating procedure. Whether you are a direct operator, a production team leader, or a technical manager, the content below will help you understand correctly, do correctly, and work safely with lifting equipment in practice.

Legal Basis for Operating Lifting Equipment in Vietnam

When discussing lifting equipment operating procedures, many people focus only on technical manipulation and forget that the first foundation of safety is legal compliance. In Vietnam, lifting equipment is classified as machinery with strict occupational safety requirements, so operation cannot be based solely on personal experience or "word-of-mouth" habits.

Mandatory Standards and Regulations

Currently, the operation of lifting equipment in Vietnam is governed by a strict legal framework, the most important of which include:

• National Technical Regulation QCVN 7:2012/BLĐTBXH on Safe Work with Lifting Appliances: This is a mandatory document prescribing minimum safety requirements throughout the equipment lifecycle: from design, installation, and use to inspection and maintenance.
• Vietnam Standard (TCVN) TCVN 4244:2005 on Lifting Appliances: These standards serve as detailed technical benchmarks, providing specific guidance on:

• • Equipment structure.

  • Safe working loads (SWL).

  • Operating conditions.

  • Methods for inspection, load testing, and technical assessment.

A crucial point that many businesses miss: When standards are updated or replaced, applying the new version is mandatory, not optional.

Legal Responsibilities of Businesses and Operators

According to regulations on occupational safety and hygiene, the Enterprise is responsible for:

• Only put into use the lifting equipment that has passed safety inspection.
• Developing Standard Operating Procedures (SOPs) suitable for each type of equipment.
• Organising safety training for operators.
• Performing periodic checks, maintenance, and servicing.

The Lifting Equipment Operator:

• Must be trained and issued a safety certificate/card.
• Must only operate the specific type of equipment for which they have been trained.
• Has the right to refuse operation if they detect that the equipment or working conditions are unsafe.

This means: If an incident occurs, responsibility lies not only with the person directly controlling the equipment but also involves the company's processes, training, and management.

Training and Safety Coaching Requirements

Lifting equipment operators belong to a labour group with strict safety requirements. Therefore:

• They must participate in initial safety training for a minimum of 24 hours before working.
• They must undergo periodic training at least once every 2 years, with a duration equal to 50% of the initial training time to update knowledge and review procedures.
• Only those who pass the examination are issued an Occupational Safety Card and permitted to operate.

Technical Principles Operators Must Understand Before Lifting

Operating lifting equipment is not just about pressing buttons or moving levers. Behind every lifting, lowering, or moving action are physical and technical principles. If you do not understand them correctly, the risk of safety increases rapidly. Understanding the nature of these principles helps you operate the equipment proactively and safely, rather than just acting out of habit.

Centre of Gravity and Load Stability

The most important principle in lifting is the Centre of Gravity (CoG). The CoG is the point at which the entire weight of the load is balanced. For a safe lift, the load's centre of gravity must be on the same vertical line as the hook or lifting point. If the CoG is offset from this position, the inevitable consequence is that the load will tilt, causing uneven force distribution on cables, chains, or rigging gear. This situation significantly increases the risk of load slippage, hook disengagement, or even breakage of load-bearing components.

In reality, many unfortunate accidents happen simply because centring was ignored, especially with asymmetrical objects. Therefore, an immutable rule before lifting is that the operator must clearly identify the shape, mass, and position of the object's centre of gravity.

Load Chart

Equipment such as forklifts, mobile cranes, and tower cranes all have a Load Chart provided by the manufacturer. It is a technical tool showing the inverse relationship between lifting radius (reach) and lifting capacity. The core principle of the load chart is:

• The greater the reach, the lower the allowable load.
• The greater the lifting height, the lower the stability.

This means a device can lift a large load at close range, but when extending the boom far out or lifting high, the safe load decreases significantly. Operators must always cross-check the actual load against the load chart posted in the cabin.

Pendulum Effect (Swing) When Moving Loads

With suspended lifting equipment like overhead cranes, gantry cranes, and hoists, the load is hung by cables or chains—essentially a simple pendulum system. When the trolley or bridge moves, the load tends to lag due to inertia, then swings forward when the vehicle stops, creating a pendulum motion. This swinging causes lateral forces on the steel structure, rapidly wearing out mechanical parts, and is particularly dangerous for personnel working below. Lateral forces can also cause the load to collide with surrounding obstacles.

Safety Principles of Brakes and Cables

Most modern lifting equipment uses normally closed safety brakes to ensure maximum safety. Under this principle, the spring force always presses the brake pads against the drum or disc to hold the load fixed, and it only opens when the system is energised. This mechanism helps limit load dropping in case of failure, but it is only effective if the brakes and cables are in good condition.

Wire rope is the main load-bearing detail, composed of many strands twisted together. Due to high load bearing, the condition of the cable must strictly comply with safety standards like TCVN 4244 and ISO 4309. Periodic inspection is mandatory to determine timely replacement. Specifically, the cable must be discarded immediately if it falls into one of the following cases:

• The number of broken wires in one lay length exceeds 10% of the total number of wires.
• The actual diameter of the cable is reduced by more than 7% compared to the nominal diameter.
• Serious mechanical deformations appear, such as "bird-caging," kinking, or crushing.

Standard Lifting Equipment Operating Procedure

To ensure safety, every piece of lifting equipment—whether an overhead crane, hoist, forklift, or assistive device—needs to be operated according to a unified procedure, without shortcuts or intuition. Vietmani recommends applying a mandatory 3-phase process: Before – During – After operation.

Phase 1 – Pre-Operation Check

This is a mandatory step, serving as a "risk screen" at the start of the shift. You are not allowed to operate if any item does not meet requirements.

Check the Work Environment:

• The lifting area must be tidy and free of obstacles.
• Ensure sufficient lighting and non-slippery surfaces.
• No people standing in the danger zone below or around the load.

Check Equipment Condition:

• Hooks, forks, lifting frames: No cracks, bending, or deformation.
• Cables, chains, slings: No broken strands, kinks, or excessive wear.
• Brakes, lifting mechanisms: Operate normally, no unusual noises.
• Control system: Buttons, levers, and remotes work accurately.
• Emergency Stop (E-stop): Test to ensure effectiveness.

Check the Load and Rigging Gear:

• Clearly determine the load weight.
• Ensure the load does not exceed the Safe Working Load (SWL).
• Slings, hooks, clamps, and vacuum lifters must be suitable for the load and shape of the object.

If abnormalities are detected at any step, stop the operation and report immediately. Absolutely do not make temporary fixes just to get the job done.

Phase 2 – Lifting and Moving the Load

This is the most dangerous phase, requiring high concentration and strict adherence to technique.

Step 1: Hooking and Centring:

• Hook the load at the correct centre of gravity.
• Cables or lifting devices must be vertical.
• Do not pull sideways or drag the load.

Step 2: Test Lift:

• Lift the load 10–20 cm off the ground.
• Stop to check: Is the load balanced? Do the brakes hold well? Are there signs of slipping, tilting, or abnormalities?
• Only continue lifting if everything is safe.

Step 3: Lifting and Moving:

• Lift slowly, avoid jerky movements.
• Move the load to a sufficient height, at least 0.5 meters higher than the highest obstacle on the path.
• Do not change direction suddenly.
• Always observe the entire lifting process.
• Do not let the load pass over people's heads or populated work areas.

Step 4: Lowering the Load:

• Lower slowly to the correct position.
• Ensure the landing surface is flat and stable.
• Only unhook or remove rigging gear when the load is completely stable.

Phase 3 – Stopping and Ending the Shift

Ending the shift correctly protects the equipment and ensures safety for the next shift.

• Retract Equipment: Raise the hook high (at least 2m from the floor or near the upper limit) to avoid obstructing people and vehicles below.
• Parking Position: Move the trolley close to the cabin or power supply side. Move the bridge to the designated position.
• Power Off:

  • Press the E-Stop button on the controller to cut the control circuit.

  • Turn off the main circuit breaker powering the crane.

• Storage: Store the pendant/remote in the designated place to prevent unauthorised tampering.
• Recording: Record the operating status in the logbook, noting any abnormalities requiring maintenance.

Core Principles Throughout the Process

In every step, remember these rules:

• Do not exceed the allowable load.
• Do not stand or work under a suspended load.
• Do not operate without training.
• Do not skip the pre-shift check.
• Safety always takes priority over schedule.

Vietmani believes that when procedures are executed correctly, fully, consistently, equipment lasts longer, work flows smoother, and most importantly, people are kept safe.

Operating Overhead Cranes and Gantry Cranes Safely

Overhead and gantry cranes handle heavy loads, often working above people and machinery. A minor operating error can cause serious consequences. Vietmani recommends strict adherence to specific procedures for this equipment group.

Pre-Operation Inspection

Perform a comprehensive check before every shift.

• Work Area: Rails are clean/clear; no one on the girders/rails; area below is controlled.
• Structure/Mechanism: Hook (no cracks/deformation, safety latch works); Wire rope (no breaks/kinks/wear); Pulleys/Drums (rotate smoothly, cable in grooves); Brakes (no slip/noise).
• Electrical/Control: Remote/buttons work (no jamming); Limit switches work; E-stop works.

Startup and No-Load Test

Before lifting goods, run all mechanisms (up, down, left, right, travel) to check brakes and especially the Limit Switch. Ensure the hoist stops automatically when the hook reaches the upper limit.

Startup: Close main breaker -> Unlock control -> Reset E-Stop (twist clockwise) -> Press Start/Horn.

Hooking and Test Lift

• Hooking: Use appropriate slings/shackles; hook at the Centre of Gravity; keep lines vertical (no side-pulling).
• Test Lift: Lift 10–20cm -> Stop -> Check balance/brakes/stability. Proceed only if safe.

Lifting and Moving

• Control Swing: Lift slowly; move smoothly; no sudden acceleration/stops.
• Height: Keep the load at the necessary height only.
• Observations: Watch the path constantly.
• Prohibitions: NEVER move overhead, stand under loads, or use the crane to drag loads.

Lowering and Unhooking

• Lower slowly to a flat surface.
• Wait for the load to be completely stationary before unhooking.

Ending Operation

• Raise the hook to a safe height.
• Return trolley/bridge to parking position.
• Cut power.
• Store remote.
• Log status.

Special Notes for Tower Cranes and Mobile Cranes

Unlike stable factory environments, construction sites pose high risks due to soft ground, wind, and changing layouts. Adhere to QCVN 18:2021/BXD and TCVN 4244:2005.

Controlling Foundation and Outriggers

Ground bearing capacity is vital for mobile crane stability.

• Outriggers: Must be fully extended per manufacturer design. Locking pins must be secured.
• Cribbing/Pads: Mandatory use of pads with sufficient area to distribute pressure, especially on soft ground.

Safety Distance from Excavations

To prevent tipping due to landslides near pits:

• Sand/Gravel: 6m from edge.
• Sandy Loam: 5m from edge.
• Clay: 4m from edge.
• Loess Soil: 5m from edge.

Environmental Factors (Wind & Storms)

• Wind Limits: Do not operate (especially tower cranes) if wind speed exceeds manufacturer limits (usually Force 5 or 6).
• Weathervaning (Thả xoay): When stopped or during storms, tower cranes must "weathervane" (release the slew brake). This allows the jib to spin freely with the wind like a weather vane, minimising wind resistance and preventing structural collapse.

Safe Forklift Operation Procedure

Forklifts are flexible but prone to accidents in busy warehouses.

Pre-Operation Check

• General: No leaks (oil/water/fuel); no loose parts; Overhead Guard intact.
• Wheels: Tires not worn/cracked; correct pressure; no jamming.
• Forks/Mast: Forks straight (not bent/cracked); locking pins secure; mast moves smoothly.
• Safety: Brakes, horn, lights, mirrors, and seatbelt functioning.

Startup and Posture

• Mount correctly, sit properly.
• Fasten seatbelt (Mandatory).
• Adjust seat/mirrors.
• Warm up the engine, test brakes/steering.

Lifting and Moving Rules

• Travel Position: Forks lowered (15-20cm from ground) and mast tilted back to secure the load.
• Speed: Adhere to limits (5-10 km/h). Slow down at corners/wet floors.
• Ramps/Slopes:

• • Loaded: Drive Forward up / Reverse down (Load always faces uphill).

  • Unloaded: Drive Reverse up / Forward down (Counterweight faces uphill).

  • Prohibited: Never turn or drive diagonally on a slope.

• Stacking: Approach perpendicular and slow. Lift only when stopped. Observe Load Centre limits.

Handling a Tip-Over

If the forklift starts to tip:

1. DO NOT JUMP OUT. (Jumping leads to being crushed by the overhead guard).
2. Stay in the seat.
3. Grip the steering wheel tightly.
4. Brace your feet against the floor.
5. Lean away from the direction of the fall.

Zero Tolerance Behaviours

Vietmani classifies these as "Zero Tolerance"—a single violation is unacceptable.

• Standing/walking under a suspended load.
• Exceeding the Safe Working Load (SWL).
• Side-pulling, dragging, or non-vertical lifting.
• Bypassing/tampering with safety devices.
• Misusing equipment (wrong purpose).
• Operating without a training/health qualification.
• Subjective negligence ("shortcuts").

Communication and Safety Signals

Standard hand signals (TCVN 12434:2018) are the mandatory common language in noisy environments.

Basic Signals

• Stop: Arm extended, palm down, held rigid.
• Emergency Stop: Arms extended, palms down, waving up and down rapidly. (Anyone can signal this; the operator must stop immediately)
• Hoist Up: Arm vertical, forefinger pointing up, moving in a small circle.
• Lower Down: Arm extended downward, forefinger pointing down, moving in a small circle.
• Move Trolley/Bridge: Palm/thumb pushing in the direction of travel.
• Move Slowly: One hand signals motion, the other hand held flat above it (barrier) to indicate precision.

Coordination Rules

• "One Commander": Only one Signalman/Rigger gives commands (except for Emergency Stop).
• "Line of Sight": The signalman must see both the load and the operator. Use radios or intermediate signalmen for blind spots.

Maintenance and Its Link to Safety Operation

Maintenance is an inseparable part of safety, not just a repair task.

Why Maintenance Decides Safety

Lifting equipment endures heavy loads, high frequency, and harsh environments. Neglecting maintenance leads to hidden risks like internal wire breaks, brake fade, or electrical faults.

• Proper Maintenance: Ensures absolute load control (no drift) and precision (smooth movement).
• Neglect: Forces operators to compensate for machine faults with "tricks," increasing risk exponentially.

Basic Maintenance Items

• Daily: Visual check (cables, hooks, brakes, noises).
• Periodic: Lubrication; brake adjustment; cable/pulley wear check; bolt tightening.
• Intensive: Replace cables/pads at limits; structural checks; electrical testing; recertification.

Conclusion

Operating lifting equipment is not merely a technical task but a highly disciplined sequence of actions where every step—from inspection and operation to maintenance—directly impacts human safety and production efficiency.

When any of these factors is ignored, safety relies on luck, which is unacceptable. Vietmani believes safety comes from:

• The habit of checking equipment daily.
• Adherence to procedures, even when rushed.
• The consciousness to stop when something feels wrong.
• Putting safety above schedule.

For you—the operator or manager—following procedures is not just a duty; it is how you protect yourself, your colleagues, and your business.

Vietmani hopes this document will be:

• Applied in daily work.
• Used for internal training.
• Standardise into SOPs and checklists at your site.

Because when safety becomes a habit, efficiency and sustainability are the inevitable results.

Do you need advice on operating procedures or standard maintenance services for lifting equipment? Contact Vietmani today for a free survey - Hotline: 0931 782 489.