Procedure for Safe and Proper Operation of Lifting Equipment

In manufacturing, warehousing, or construction environments, lifting equipment is a tool that helps businesses optimise productivity, reduce manual labour, and handle loads far beyond human capabilities. However, along with high efficiency comes a significant risk to occupational safety if the equipment is not operated according to the correct procedures. So, what is the standard safe operation procedure for lifting equipment? Let's explore the details with Vietmani through the article below.

Legal basis for operating lifting equipment in Vietnam

When discussing lifting equipment operating procedures, many people often focus solely on technical operations, forgetting that the primary foundation of safety is legality. In Vietnam, lifting equipment is classified under the group of machines and equipment with strict occupational safety requirements, so operation cannot be based on personal experience or word of mouth.

Mandatory regulations and standard systems

Currently, the operation of lifting equipment in Vietnam is regulated by a fairly strict system of legal documents, the most important of which include:

1. National Technical Regulation QCVN 7:2012/BLDTBXH on occupational safety for lifting equipment: This is a mandatory document specifying minimum safety requirements throughout the equipment's life cycle, from design, installation, and use to inspection and maintenance.
2. Vietnam Standard (TCVN) TCVN 4244:2005 on lifting equipment: These standards serve as detailed technical benchmarks, providing specific guidance on:

• Equipment structure
• Safe working load (SWL)
• Operating conditions
• Methods of inspection, load testing, and technical condition assessment

A very important point that many businesses often overlook: when a standard is updated or replaced, applying the new version is mandatory, not optional.

=> See more:

• Lifting Equipment Safety Regulations: Latest 2026 Standards Update
• Lifting equipment safety regulations: Comprehensive summary of the latest QCVN and TCVN

Legal responsibilities of businesses and operators

According to regulations on occupational health and safety:

Businesses are responsible for:

• Only putting into use the lifting equipment that has passed technical safety inspections
• Developing Standard Operating Procedures (SOPs) appropriate for each type of equipment
• Organising occupational safety training for operators
• Conducting periodic inspections, maintenance, and servicing

Lifting equipment operators:

• Must be trained and issued a safety certificate/card
• Are only allowed to operate the specific type of equipment they have been trained on
• Have the right to refuse operation if they discover the equipment or working conditions do not ensure safety

This means: if an incident occurs, the responsibility lies not only with the direct operator but also with the business's procedures, training, and management.

Requirements for safety education and training

Lifting equipment operators belong to a group of workers 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 their knowledge and review procedures
• Only those who pass the assessment are issued an Occupational Safety Card and are permitted to operate

=> See more:

• Regulations on lifting equipment operators according to current laws
• Lifting equipment operation certificate – Latest regulations & penalty levels

Technical principles operators must understand before lifting

Operating lifting equipment is not just about pressing buttons or moving levers. Behind every lifting – lowering – moving operation are physical and technical principles; if you do not understand them correctly, safety risks will increase very quickly. Therefore, understanding the fundamentals will help you operate the equipment more proactively and safely, rather than just following a routine.

Centre of gravity and load stability

The most important principle in lifting is the centre of gravity.

The centre of gravity is the point at which the entire weight of the lifted object is balanced.

For a safe lifting process, the load's centre of gravity must strictly lie on the same vertical plane as the crane hook or lifting point. If the centre of gravity deviates from this position, the inevitable consequence is that the load will tilt, causing an uneven distribution of force on the cables, chains, or load-bearing equipment. This condition significantly increases the risk of slipping, unhooking, or even breaking structural components.

Reality shows that many unfortunate accidents have occurred simply because aligning the centre of gravity was neglected, especially for asymmetrical objects. Therefore, an unchangeable rule before lifting is that the operator must clearly determine the shape, mass, and centre of gravity of the object.

Load chart

For equipment such as forklifts, mobile cranes, and tower cranes, each comes with a load chart provided by the manufacturer. It is a technical tool illustrating the inverse relationship between the lifting radius (reach) and the allowable lifting capacity.

The core principle of the load chart is:

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

This means an equipment piece might be able to lift a heavy load at a close range, but when extending the boom further or lifting higher, the safe capacity will decrease significantly. Thus, operators must always compare the actual load with the load chart affixed in the cabin.

Pendulum effect when lifting and moving loads

With suspended lifting equipment like overhead cranes, gantry cranes, and hoists, the load is suspended by cables or chains – essentially forming a simple pendulum system. When the trolley or bridge moves, the load will tend to lag due to inertia, then swing forward when the vehicle stops, creating sway.

This swaying generates lateral forces on the steel structure, causing rapid wear on mechanical parts and posing significant danger to personnel working below. Lateral forces can also cause the load to crash into surrounding obstacles.

Safety principles of braking and cable systems

Most modern lifting equipment uses normally closed safety brakes to ensure maximum safety. According to this principle, spring force always presses the brake pads tightly against the drum or disc to hold the load in place, and it only opens when the system is powered. This mechanism helps prevent load drops in the event of a power failure, but it is only effective if the brakes and cables are in good condition.

The wire rope is the main load-bearing component of the equipment, made up of multiple strands twisted together. Due to the nature of carrying heavy loads, the condition of the cable must strictly comply with safety standards such as TCVN 4244 and ISO 4309.

Periodic inspection is mandatory to determine the timely replacement of cables. Specifically, a cable must be discarded immediately if it falls into one of the following cases:

• The number of broken wires in a lay length exceeds 10% of the total wires.
• The actual diameter of the rope is reduced by more than 7% compared to its nominal diameter.
• Severe mechanical deformations appear, such as "birdcaging", corkscrewing, or kinking.

Standard lifting equipment operating procedure

To ensure safety, all lifting equipment – whether overhead cranes, hoists, forklifts, or power-assisted lifting devices – must be operated according to a unified procedure, without shortcuts or acting on feeling. Vietmani recommends applying a mandatory 3-stage procedure: before, during, and after the operation.

Stage 1 – Pre-operation inspection

This is a mandatory step that acts as a "risk filter" right at the start of the shift. You are not allowed to operate if any item fails to meet the requirements.

1. Inspect the work environment

• The lifting area must be tidy and free of obstacles
• Ensure adequate lighting and non-slip conditions
• No personnel should be standing in the danger zone below or around the load

2. Check equipment condition

• Crane hooks, forks, masts: no cracks, bends, or deformations
• Cables, chains, slings: no broken strands, no twists, not worn beyond limits
• Brakes, lifting mechanisms: operating normally, no unusual noises
• Control systems: push buttons, joysticks, and remotes are functioning accurately
• Emergency stop button (E-stop): test to ensure it works

3. Check the load and lifting tackle

• Clearly determine the load's mass
• Ensure the load does not exceed the allowable capacity
• Slings, hooks, clamps, and suction cups must be suitable for the load and its shape

If any abnormality is detected at any step, you must stop operations and report it immediately; absolutely do not "make do" to finish the job.

Stage 2 – Lifting, lowering, and moving operations

This is the most dangerous stage, requiring the operator to maintain high concentration and adhere strictly to proper techniques.

Step 1: Hooking the load and centring

• Hook the load precisely at its centre of gravity
• Wire ropes or lifting tackles must be vertical
• Do not pull at an angle, do not drag the load

Step 2: Test lift

• Lift the load about 10–20 cm off the ground
• Stop to check:

  • Is the load balanced?

  • Are the brakes holding the load securely?

  • Are there any signs of slipping, tilting, or abnormalities?

Only continue lifting if everything is safe.

Step 3: Lifting and moving the load

• Lift slowly, avoid jerky movements
• Move the load to a sufficient height, at least 0.5 meters higher than the highest obstacle in its path.
• Do not change direction suddenly
• Always observe the entire lifting and lowering process
• Do not move the load over people's heads or areas where people are working

Step 4: Lowering the load

• Lower the load slowly and precisely into position
• Ensure the resting surface is flat and sturdy
• Only detach hooks or tackles when the load is completely stable

=> See more: The 3-3-3 rule in lifting: The gold standard for ensuring occupational safety

Stage 3 – Finishing and shutting down the equipment

Ending the shift properly will help protect the equipment and ensure safety for the next shift.

1. Retract the equipment: Raise the crane hook to a high position (at least 2m from the floor or close to the upper limit) so it does not obstruct pedestrians or vehicles below.
2. Parking position: Move the trolley close to the cabin or the power supply side. Move the overhead crane to its designated position.
3. Disconnect power:

• Press the E-Stop button on the pendant to cut the control circuit.
• Turn off the main circuit breaker supplying power to the crane.
• Store the pendant/remote in its designated place to prevent unauthorised tampering.

Record keeping: Log the operating status in the logbook, paying special attention to any abnormalities requiring maintenance checks.

Overarching principles throughout the process

In all operating steps, you must remember the following principles:

1. Do not exceed the allowable load capacity
2. Do not stand or work under suspended loads
3. Do not operate without prior training
4. Do not skip the pre-shift inspection
5. Safety always takes priority over schedule

Vietmani believes that when operating procedures are performed correctly, fully and consistently, the equipment will last longer, work will flow more smoothly, and most importantly, personnel will be kept safe.

Safe and technically correct operation of overhead and gantry cranes

Overhead cranes and gantry cranes are a class of lifting equipment that handle heavy loads and frequently operate above personnel and machinery. Even a minor error in operation can cause severe consequences. Therefore, Vietmani highly recommends that you strictly follow specific procedures for this equipment group, rather than applying general rules like with other lifting devices.

Pre-operation inspection for overhead and gantry cranes

Before every shift, you must conduct a comprehensive inspection, leaving no item unchecked.

Inspect the work area

• Crane runways must be clean and free of obstacles
• No personnel working on the girders, rails, or within the danger zone
• The area beneath the load must be warned and controlled

Inspect structures and lifting mechanisms

• Crane hook: no cracks, no bending, safety latch working well
• Wire ropes: no broken strands, no twisting, not worn beyond allowable limits
• Pulleys, winch drums: spinning freely, cables seated correctly in grooves
• Hoist brakes: no slipping, no unusual noises

Inspect electrical and control systems

• Pendants/remotes functioning accurately, no stuck buttons
• Limit switches are working normally
• Emergency stop button (E-stop) ensuring effectiveness

If you detect any abnormal signs, you must stop operating immediately and notify the technical department for resolution.

Startup and no-load testing

Before lifting goods, you must test-run all mechanisms (up, down, left, right, travel) to check brake operations and especially the Limit Switches. Ensure that when the crane hook reaches its upper limit, the hoist stops automatically.

Electrical system startup procedure:

1. Turn on the main circuit breaker at the power supply panel.
2. Unlock the control key (if applicable).
3. Check the E-Stop: Twist the E-Stop button on the pendant/remote clockwise to release the lock. Wait 1-2 seconds for the system to boot up and synchronise signals (for remote controls).
4. Press the "Start/On" button or sound the horn to activate the main contactor.

Hooking the load and test lifting

Proper load hooking technique

• Use slings, chains, and shackles suitable for the load weight
• The crane hook must be placed exactly at the load's centre of gravity
• Slings must be vertical, no angle pulling

Test lifting

• Lift the load about 10–20 cm off the ground
• Stop to check:

  • Is the load balanced?

  • Are the brakes holding the load firmly?

  • Are there any strange noises or abnormal vibrations?

Only proceed with the lift when all conditions are safe.

Lifting and moving loads with overhead and gantry cranes

While lifting and moving the load, pay special attention to the pendulum effect.

• Lift the load slowly, avoiding jerks
• Move the trolley and bridge smoothly and steadily
• Do not accelerate or stop suddenly
• Keep the load at a sufficient height; do not lift unnecessarily high
• Always keep an eye on the load's entire path

Strictly prohibited:

• Do not move loads over people's heads
• Do not stand under a suspended load
• Do not use the crane to drag or angle-pull heavy objects

Lowering the load and unhooking

• Lower the load slowly to the predetermined position
• Ensure the resting surface is flat and stable
• Only unhook when the load is completely stationary
• Do not unhook while the load is still suspended or unstable

Finishing overhead and gantry crane operations

After completing your tasks, you must shut down the equipment properly:

• Raise the crane hook to a safe position to avoid snagging
• Move the trolley and crane bridge to their designated positions
• Disconnect the power supply
• Store the pendant/remote in its designated place
• Record the equipment's condition in the operation logbook

Special precautions when operating tower cranes and mobile cranes

Unlike the stable factory environment, construction sites pose significantly higher risks due to soft ground, wind and storm impacts, and constantly changing site layouts. Therefore, when operating tower cranes and mobile cranes, QCVN 18:2021/BXD and TCVN 4244:2005 must be strictly adhered to.

Foundation and Outrigger Control

The load-bearing capacity of the soil is a life-or-death factor for the stability of a mobile crane.

• Outriggers: Must always be fully extended according to the manufacturer's design. The outrigger lock pins must be securely engaged to prevent slipping.
• Cribbing/Pads: It is mandatory to use outrigger pads with a sufficiently large area and adequate rigidity to evenly distribute pressure to the ground, particularly crucial when working on soft or yielding soil.

Safe Distances from Excavations

When positioning equipment near the edge of a trench or deep excavation, the risk of soil collapse leading to crane overturns is massive. You must comply with minimum safe clearance distances based on the soil type and excavation depth. Below are reference distances:

• Gravel/sandy soil: 6m from the edge
• Loamy sand: 5m from the edge
• Clay soil: 4m from the edge
• Loess soil: 5m from the edge

Environmental Factor Control (Wind & Storms)

The QCVN 18:2021 regulation sets very strict limits on wind speeds during operation:

• Operating limits: Absolutely do not operate lifting equipment (especially tower cranes and hoists) when the wind speed exceeds the manufacturer's allowable threshold (typically level 5 or 6).
• Safety mechanism during storms ("Weathervaning"): When operations cease or during storms, tower cranes must undergo the "weathervaning" procedure. Let the jib slew freely downwind like a weather vane. This minimises wind resistance area and prevents the risk of boom failure or tower collapse due to excessive lateral wind forces.

=> See more: Crane safety factor: TCVN regulations & Detailed calculation formulas

Safe forklift operating procedures

Compared to overhead or gantry cranes, forklifts offer higher flexibility but also harbour significant accident risks, especially in crowded warehouses, narrow aisles, and continuous movement. Most forklift incidents stem from driver errors or negligence while moving, rather than equipment failure.

Therefore, Vietmani recommends fully adhering to the forklift operating procedures outlined below.

Pre-operation forklift inspection

Before each shift, the forklift driver must inspect the vehicle's condition. This is a mandatory step that must not be skipped, even if the vehicle was just used in the previous shift.

Overall inspection

• No oil, water, or fuel leaks
• No unusually loose, cracked, or bent parts
• The overhead guard is intact

Inspect wheels and drivetrain

• Tires are not excessively worn, no cracks or blowouts
• Tire pressure is adequate (for pneumatic tyres)
• Wheels are not stuck and do not vibrate abnormally

Inspect the forks and mast

• Forks are not bent or cracked
• Fork locking pins are secure
• The mast raises and lowers smoothly, without jerking

Inspect safety and control systems

• Foot brakes and handbrakes work well
• Horn, lights, and mirrors are present and clear
• The seat belt is in good usable condition

If any unsafe signs are detected, you must stop the vehicle immediately and notify the technical department; absolutely do not attempt to operate it.

Starting and operating the forklift in the correct posture

• Mount the vehicle correctly, sitting squarely in the driver's seat
• Fasten the seat belt before starting the engine
• Adjust the seat and mirrors for optimal visibility
• Start the vehicle and let the engine idle briefly
• Test the brakes and steering wheel before moving

Procedures for lifting and handling goods

Movement rules:

1. Fork posture: When moving (loaded or unloaded), the forks must be lowered to about 15cm - 20cm above the ground, and the mast must be tilted back fully. This keeps the centre of gravity low and prevents goods from slipping off the forks.
2. Speed: Adhere to designated speed limits inside the factory (usually 5-10 km/h). Slow down when cornering, on slippery surfaces, or passing through doorways.
3. Navigating Ramps:

• When loaded: Always point the front of the vehicle (the loaded side) uphill. That means: Drive forward up the ramp, and reverse down the ramp. This prevents the load from slipping off the forks.
• When unloaded: Always point the rear of the vehicle (the heavier counterweight side) uphill. That means: Reverse up the ramp, and drive forward down the ramp.
• Prohibited: Absolutely never turn around or travel diagonally on a ramp; the vehicle is highly prone to tipping over sideways.

Loading and unloading rules:

• When approaching racks, drive perpendicularly and slowly.
• Raise the forks to the required height, then move forward slowly.
• Absolutely do not raise or lower the forks while the vehicle is in motion (except for minor adjustments to enter a pallet).
• Ensure the load does not exceed the allowable capacity at the specified Load Centre.

Handling a tip-over emergency

This is the most crucial knowledge that can save a driver's life. If the forklift starts to tip over (sideways or forwards/backwards):

1. ABSOLUTELY DO NOT JUMP OUT OF THE VEHICLE. Statistics show that most fatalities occur because the driver tries to jump out and gets crushed by the vehicle's overhead guard.
2. Stay seated in the driver's seat.
3. Brace yourself by gripping the steering wheel or assist handle tightly.
4. Press your feet firmly against the floor to stabilise your body.
5. Lean your body in the opposite direction of the tip.

This is why wearing a seat belt is mandatory: it keeps the driver safely inside the vehicle's "protective cage" when an accident occurs.

Strictly prohibited actions when operating lifting equipment

In lifting equipment operations, there are minor mistakes that can be corrected with a warning, but there are also behaviours that are absolutely not permitted under any circumstances. Vietmani refers to these as "Zero Tolerance" behaviours – committing them even once can lead to severe accidents or irreversible consequences.

1. Standing, walking, or working underneath suspended loads
2. Lifting beyond the equipment's allowable capacity
3. Angle pulling, dragging, or lifting a load non-vertically
4. Disabling or tampering with safety devices
5. Using lifting equipment for purposes other than its intended design
6. Operating without prior training or when not physically fit
7. Being overconfident, skipping procedures because you are "used to it"

Communication and safety signalling systems

In noisy construction environments, verbal communication is often impossible and easily leads to disastrous misunderstandings. Therefore, hand signal systems standardised according to TCVN 12434:2018 are considered the mandatory common language to ensure safety.

Basic signals

Stop Signal Group:

• Stop: One arm extended horizontally at shoulder level, palm facing down, and held stationary.
• Emergency Stop: Both arms extended horizontally at shoulder level, palms facing down, waving rapidly up and down.

Special note: This is the highest priority signal. Anyone on site (even if not the designated signalman) has the right to issue this signal upon spotting danger, and the operator must stop the machine immediately.

Hoist/Lower Signal Group:

• Hoist Up: Arm bent vertically, index finger pointing straight up toward the sky, moving in small circles.
• Lower Down: Arm extended downward, index finger pointing to the ground, moving in small circles.

Move & Micro-adjust Signal Group:

• Move trolley/bridge: Use thumb or palm to point in the direction of intended travel.
• Move Slowly: One hand gives a motion signal (e.g., hoist/lower), while the other hand is placed flat and motionless above it (like a barrier) to indicate the need for slow, precise operation.

Coordination rules

To avoid "Chinese whispers" during the lifting process, the work crew must strictly follow these 02 principles:

1. "One Commander" Principle: At any given time, there is only allowed to be a single designated signalperson (rigger) responsible for issuing commands to the operator. Except for the Emergency Stop command.
2. "Line of Sight" Principle: The signalperson must stand in a position with a clear view of both the load and the operator. In cases of obstructed views (blind spots), it is mandatory to use supplementary equipment (two-way radios) or deploy intermediate signal persons to relay signals.

Maintenance – servicing and its connection to operational safety

Many still believe that merely operating correctly is enough for safety. In reality, safe operation procedures are only effective when the equipment is in good technical condition. A lifting device, even if controlled properly, still harbours constant accident risks if the brakes are worn, the cables are degraded, or the drivetrain is damaged.

Vietmani views maintenance and servicing as an inseparable part of operational safety, not just an ad-hoc task when the equipment breaks down.

Why does maintenance determine the level of safety?

Safety in lifting equipment operations is intrinsically tied to maintenance work, as the operating nature of this equipment group is extremely harsh. They continuously bear heavy loads with repetitive high-frequency work cycles while being directly exposed to environmental factors like dust, moisture, temperature, and vibrations.

If periodic maintenance is neglected, hidden risks will accumulate over time, making it hard for managers to notice immediately. Typical examples include wire ropes wearing out or snapping internally, which is very difficult to detect with the naked eye; braking systems losing their holding torque; or lifting mechanisms operating unstably, causing jerky movements. In addition, degraded electrical systems are a ticking time bomb with a high risk of short circuits and fires.

Reality has proven: Many severe accidents occur not due to operator errors, but because the root cause was the equipment's failure to maintain a technically safe state – the inevitable consequence of a lack of maintenance.

Basic maintenance and servicing items to execute

Daily / Pre-shift Maintenance

• Visually inspect cables, hooks, and chains
• Check brakes and emergency stop buttons
• Early detection of unusual noises or vibrations

Periodic Maintenance

• Lubricate moving parts
• Inspect and adjust brakes
• Check the wear on cables, hooks, and pulleys
• Tighten bolts and connections

In-depth Servicing

• Replace cables and brake pads when they reach their limits
• Inspect load-bearing structures
• Test electrical systems and motors
• Conduct technical safety inspections as regulated

Safety does not rest solely in the operator's hands but relies on the synergy between people, equipment, and procedures. When equipment is maintained to standards, operators are fully trained, and procedures are strictly adhered to, safety becomes the inevitable outcome, not just a hope.

Conclusion

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

When any of these elements is ignored, safety relies on luck, which is a scenario no business or worker desires.

Vietmani believes that safety does not come from wall slogans, but from:

• The habit of inspecting equipment every day
• Compliance with procedures, even when tasks are urgent
• The consciousness to stop when something doesn't feel right
• And the mindset of prioritising safety over schedule

For you, the direct operator or manager of lifting equipment, doing things the right way is not just a responsibility but also a means to protect yourself, your colleagues, and your business.

Vietmani hopes this document does not merely serve as reading material, but will be:

• Applied by you in daily work
• Used as an internal training resource
• Standardised into SOPs, checklists, and on-site safety regulations

When safety becomes a habit, efficiency and sustainability will be the inevitable results.

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