Foundation Certificate (Global)

Course
Handbook
Lifting standards worldwide.

Version 3 - Copyright @ 2025 by LEEA

Welcome
Handbook Contents | 1 - 4

Handbook Contents

WELCOME 8

Introduction 9

COURSE OVERVIEW 10

Course Handbook 11

Required Activities 12

Case Studies - An Introduction 15

BRIEF HISTORY 17

Lifting Equipment of the Past 18

History of LEEA 21

MODULE A - LEEA’s Behaviours for a Safer World of Work 24

A.1. Learning Outcomes 25

A.2. Safety, Competence and Professionalism 26

A.3. Reflective Learning 29

A.4. Knowledge Check 31

MODULE B - Legislation and Regulations 32

B.1. Learning Outcomes 33

B.2. Legal Systems 34

B.3. Regulations 39

B.4. Duty Holders 41

B.5. Consequences of Not Managing Health and Safety 44

B.6. Reflective Learning 47

B.7. Standards 51

B.8. Codes of Practice 52

B.9. Guidance 53

B.10. Best Practice 54

B.11. Knowledge Check 55

MODULE C - Managing Risk 58

C.1. Learning Outcomes 59

C.2. Primary Reasons for Risk Assessment 60

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Handbook Contents | 2 - 4

C.3. Common Workplace Hazards 61

C.4. Control Measures 64

C.5. Reflective Learning 66

C.6. The Five Steps to Risk Assessment 67

C.7. Reflective Learning 68

C.8. Knowledge Check 71

MODULE D - Industry Relevant Definitions 73

D.1. Learning Outcomes 74

D.2. Competent Person 75

D.3. Reflective Learning 78

D.4. Common Units of Measure 79

D.5. Lifting Equipment Categories, Accessories, and Appliances: 81

Definitions

D.6. Effect of Working Angles 82

D.7. Single and Multi-Purpose Equipment 84

D.8. Minimum Breaking Load (MBL) 85

D.9. Factor of Safety 86

D.10. Working Load Limit (WLL) 87

D.11. Safe Working Load (SWL) 89

D.12. Hazardous Duties 90

D.13. Rated Capacity 91

D.14. Inspection and Examination 92

D.15. The Report of Thorough Examination 94

D.16. Reflective Learning 95

D.17. Knowledge Check 98

MODULE E - Manufacturing of Lifting Equipment 101

E.1. Learning Outcomes 102

E.2. Duties of the Manufacturer 103

E.3. Verification and Load Testing 107

E.4. Conformity and Documentation 108

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Handbook Contents | 3 - 4

E.5. Reflective Learning 114

E.6. Knowledge Check 116

MODULE F - MATERIALS AND THEIR PROPERTIES 118

F.1. Learning Outcomes 119

F.2. Characteristics and Forces 120

F.3. Material Properties 124

F.4. Metals 126

F.5. Plastics 128

F.6. Natural Fibres 128

F.7. Heat Treatment 129

F.8. Stress and Strain 130

F.9. Reflective Learning 131

F.10. Knowledge Check 132

MODULE G - LIFTING ACCESSORIES 133

G.1. Learning Outcomes 134

G.2. Chain Slings 135

G.3. Wire Rope Slings 138

G.4. Textile Slings 140

G.5. High Modulus Polyethylene (HMPE) 142

G.6. Shackles 143

G.7. Eyebolts 146

G.8. Hoist Rings 147

G.9. Load Lashing Equipment 148

G.10. Reflective Learning 150

G.11. Knowledge Check 151

MODULE H - LIFTING APPLIANCES 153

H.1. Learning Outcomes 154

H.2. Bridge and Gantry Cranes 155

H.3. Supporting Structures 157

H.4. Supporting Structures (Continued) 161

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Handbook Contents | 4 - 4

H.5. Manual Lifting Machines 164

H.6. Manual Lifting Machines (Continued) 167

H.7. Powered Lifting Machines 171

H.8. Reflective Learning 174

H.9. Knowledge Check 179

MODULE I - Purchasing and Control of Lifting Equipment 181

I.1. Learning Outcomes 182

I.2. Purchaser’s Responsibilities 183

I.3. Marking, Storage and Handling 186

I.4. Maintenance and Inspection 188

I.5. Training and Safe Use 190

I.6. Disposal 194

I.7. Reflective Learning 195

I.8. Knowledge Check 199

SUMMARY 201

Key Messaging 202

Feedback 207

Personal Commitment 208

Assessment Information 210

Thank You 211

Welcome
Course Handbook | Introduction

Introduction
This course aims to provide you with a powerful insight into the world of lifting equipment, offering you the
necessary foundation knowledge to perform your duties safely and efficiently.

You can find more information about the structure of this course in the infographic below:

Assessment Criteria
• Case Studies
• Reflective Learning Assignments
• Reflective Statements
• Knowledge Checks
• Feedback
• Personal Commitment
• Multiple-Choice Assessment

Further Support
You can find more detailed information about these activities in the Course Overview section.

Should you require assistance throughout your studies, please email academysupport@leeaint.com
providing a brief outline of your query and we will be delighted to help you.

Continue onto the next page to start the course.

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Course Overview

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Course Overview | Course Handbook

Course Handbook
To help you in your learning journey, LEEA has designed a Course Handbook. You can use it as a point of
reference, or as a place to make notes as you navigate the course.

You can always access a digital copy of this file by selecting the download button available on the
interacrtive PDF version of the Course Handbook, or the online learning course from any mobile device.

This will take you to Dropbox, where you can download a copy for your own reference. Once there, click on
the Download button at the top of the page. See screenshot below.

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Course Overview | Required Activities Required Activity
!
Required Activities
Whenever you see the blue label with “Required Activity!”, make sure you complete the activity in order to
pass the course successfully.

Assessed Modules

This Foundation Certificate course is structured on two primary components:

• Learning Outcomes:
What you should know and do throughout the course.
• Assessment Criteria:
What will be expected of you to demonstrate achievement of the learning outcomes.

Each module will have these two components stated at the beginning of the section. See screenshot below:

Types of Required Activities

To successfully complete this course, you must engage with the following types of activities. These have
been designed to enhance your understanding of the course content and help you relate the information to
real-life scenarios.

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Course Overview | Required Activities

The case studies will focus on our fictional organisations, Osprey Lifting and Turbo Engineering.

They will be scenario based involving characters, premises and equipment from both organisations and
other external bodies such as enforcing authorities, suppliers and customers.

The case studies will encourage you to use your learning in order to identify and solve issues and problems,
applying your new knowledge as you progress through the course.

Reflective Learning Assignments are presented as multiple-choice questions or hyperlinks to tasks you
need to complete on a different window.

You can find these as part of the case studies, or after a complex piece of information. They are designed
to help you retain course content and further develop the train of thought you will need in real-life
scenarios.

You can find these statements throughout the course. They provide a different insight relating to both the
content course, and the case studies, inviting you to reflect about the situation.

Knowledge checks are designed to help you test your knowledge and understanding of each particular
module. They are an excellent opportunity to identify your strengths and areas for improvement,
highlighting what modules might need revisiting for additional studying. Knowledge checks are presented in
the format of multiple-choice questions. These will contribute to your overall score.

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Course Overview | Required Activities

End of Course Required Activities

Once you have gone through all the modules in the course, you will be asked to interact with the following
activities. These are all mandatory to officially mark the course as complete.

Feedback
At LEEA, we value continuous improvement, which is why we ask you to provide us with feedback
about your learning experience.

The online feedback form will be available at the end of the course.

Personal Commitment
As part of our continuous improvement strategy, you are required to complete a personal
commitment form. This document encourages you to come up with three SMART goals that will
help you on your professional development journey.

One of the goals must be related to LEEA’s Behaviours for a Safer World of Work, which you will
learn more about in the first module of this course.

We recommend you go back to your “Personal Commitment” document at the end of each training
day to keep your goals relevant to the content of the course.

If you are accessing the Course Handbook through a mobile device, you can select the Download
button below to access a digital copy of the “Personal Commitment” file. Alternatively, turn to
page 208-209 in of this document.

Multiple-Choice Assessment
Following completion of the course, you will have 30 days to complete the final assessment.
This is made of 50 multiple-choice questions drawn directly from the learning outcomes and
assessment criteria of the course.

Once you start, you will have 50 minutes to complete your assessment in the LEEA Academy App.

The pass mark for the assessment is 75%.

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Course Overview | Case Studies - An Introduction

Case Studies - An Introduction

Case studies are a great opportunity for you to explore real-life scenarios in a safe online environment,
where you can learn from the choices you make.

The case studies in this course are designed to reinforce and support the learning outcomes and
assessment criteria stated for each module throughout the course.

LEEA has created two virtual organisations:

• Turbo Engineering
• Osprey Lifting

These two companies will face a series of opportunities and challenges throughout the course. You
will need to answer questions and suggest solutions. Your performance will be assessed in terms of
knowledge application, skill and behaviour based on the information you encounter to that point.

Key Point:
Your answers will form part of your learning record and will be monitored by the LEEA training
team.

Osprey Lifting’s services include maintenance, inspection, installation, repair and modernisation of all lifting
equipment including bridge and gantry cranes, powered and manual lifting machines, supporting structures
and lifting accessories.

This company offers mobile cranes, tower cranes and offshore container inspection services. They are also
an approved supplier and installer of work-at-height safety equipment and load-lashing equipment.

Study the diagram below, to understand Osprey Lifting’s organisational structure.

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Course Overview | Case Studies - An Introduction

Turbo Engineering was originally formed to repair and maintain tractors and a wide range of agricultural
machinery.

The organisation has since expanded into a diverse range of business areas including, but not limited to oil
and gas, renewables, marine, ports and shipping sectors.

CEO

Operations Sales & Business Technical & Engineering

Manager Development Manager Manager

• Maintenance • Tractor & Agricultural Machinery

• Agricultural Machinery Sales
• Repair Team Engineering
• New Business Ventures
• Expansion Projects Team (Oil & • New Business Ventures
• Client Relations & Customer Service
Gas, Renewables, • Client Relations & Customer Service
Marine/Ports/Shipping)

Summary
Throughout the course, you will encounter these two companies in scenarios that illustrate real-
life challenges. These examples will prompt you to think critically, reflect on best practices, and
reinforce your understanding of key terms and concepts as you progress.

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Brief History

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Brief History | Lifting Equipment of the Past

Lifting Equipment of the Past

A Brief History
Defying gravity is nothing new. Our ancestors engineered ways to create iconic structures over 5000
years ago. Today, we continue to follow in their footsteps.

From Stonehenge in England, and the Pyramids of Giza in Egypt, to the Chrysler Building in New York,
U.S.A. and the Burj Khalifa in Dubai, U.A.E., our industry continues to engineer innovative means to
defy gravity with the highest regard for health and safety, striving to eliminate accidents, injuries and
fatalities in the lifting equipment industry.

Lifting Events in the Neolithic Period

Stonehenge
Stonehenge is a prehistoric monument located in Wiltshire, England. It is one of the most famous landmarks
in the United Kingdom and is composed of a ring of standing stones, each around 13 feet high, 7 feet wide,
and weighing approximately 25 Tons.

Stones were likely erected using a combination of manpower, wooden scaffolding, and simple machines
such as levers. Stonehenge was constructed in several stages. The earliest work dates back to around
3000 BC. The main construction phases occurred between 3000 BC and 2000 BC.

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Brief History | Lifting Equipment of the Past

Lifting Events in the Middle Ages

The Treadwheel Crane

The Treadwheel Crane, also known as a treadmill crane or a medieval crane, is a historical construction
device used for lifting heavy loads. It was particularly common in medieval Europe from the Roman
period through the Middle Ages and into the Renaissance.

The wheel is large enough to allow workers to walk inside it, similar to a hamster wheel. As they walk, they
turn the wheel, which in turn operates the lifting mechanism. The ratio between the treadwheel and the
lifting shaft creates a mechanical advantage and heavy loads could be lifted compared to the effort put in
by the treadwheel operators.

The illustration below indicates the size relationship of the treadwheel to that of the lifting shaft:

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Brief History | Lifting Equipment of the Past

First Laws for the Lifting Industry

The Code of Hammurabi

Written during the reign of King Hammurabi of Babylon (1755-1750 BC) is one of the earliest records
of ancient laws which established 282 laws inscribed in a huge stone pillar. The code prescribed harsh
punishments for those found guilty of causing harm to another and their family or belongings; a principle of
retaliatory justice.

Ancient Roman Laws and Regulations

The Romans implemented various laws concerning construction safety, including regulations governing the
use of cranes and hoisting devices. While specific texts are limited, Roman engineers like Vitruvius, in his
work “De Architectura” (On Architecture) from the 1st Century BC, highlighted the importance of safety in
construction practices. He provided guidance on using appropriate lifting equipment, emphasizing the need
for suitable materials and techniques. Vitruvius’s writings demonstrate a strong understanding of the risks
involved in lifting heavy loads and the importance of implementing safe practices in construction.

The Health and Morals of the Apprentices Act

Fast-forward almost 4000 years to 1802 AD, the earliest recorded legislative intervention in the cause of
health and safety dates from the Health & Morals of Apprentices Act established in England.

The Act prevented apprentices working at night and for longer than 12 hours a day, and made provision for
them to receive some basic education.

The Factories Act 1961

In the UK, before LOLER (Lifting Operations and Lifting Equipment Regulations) was established in 1998,
the The Factories Act, established in 1961 applied to various types of machinery, including prime movers,
transmission machinery, hoists, lifts, chains, ropes, cranes and other machinery. The Act was broadly
adopted in some other countries whilst developing their own specific laws for lifting equipment.

The Act extended its provisions to warehouses and dock premises, treating them as if they were factories.
Employees had to keep records of examinations and inspections of lifting gear, making sure they followed
construction and maintenance requirements related to the quality of materials used, as well as the provision
of a safe working environment through load marking and registration.

As mentioned, this Act was later updated and consolidated in what we now know as LOLER which provides
more detailed requirements and regulations applicable to the modern world.

Summary
In current times, we see that countries have developed more specific laws dealing with a variety of
hazardous areas such as chemicals, electricity and of course lifting. As lifting equipment has evolved
and advanced, so too has legislation in order to keep people safe by mitigating risk. New Zealand’s
Maritime Rules - Ships’ Part 49: Lifting Appliances is an example of national legislation resulting from the
evolution of lifting equipment laws.

There are current international conventions that regulate lifting equipment in certain sectors. An
example of this is the IMO (International Maritime Organization) Convention for the Safety of Life at
Sea (SOLAS 1974) under which the ‘Guidelines for Lifting Appliances’ are provided in MSC.1/Circ1663,
published 28 June 2023.

Note: IMO is part of the ILO (International Labour Organization) which now has 187 member countries.

Modern legislation will be covered in more detail in Module B: Legislation and Regulations.

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Brief History | History of LEEA

History of LEEA
LEEA was established in 1944 as the Chain Tester’s Association. Since then, it has supported its
stakeholders in eliminating accidents, injuries and fatalities.

Association’s Nine people from eight companies meet to establish the

1944 Beginning London Chain Testers’ Association.

The idea to form an association to take on the might of the UK government was conceived
and the London Chain Testers Association was founded. The Association made quick progress
on negotiations with the government and soon turned its attention to other areas where
cooperative action would be mutually beneficial.

Name Growth outside London leads to a name change. We

1946 Change become The Chain Testers Association of Great Britain.

In 1946, as the Association’s boundaries extended across the UK, there was a name change to
the Chain Tester’s Association of Great Britain.

First The first Chain Testers Handbook is written and

1953 Handbook published.

First The first examination scheme for lifting equipment

1959 Examination engineers is developed and rolled out.

Code of The initial Code of Practice for the Safe Use of Lifting
1981 Practice Equipment is launched.

The Code of Practice for the Safe Use of Lifting Equipment (COPSULE) was launched.

Correspondence
1983 Courses
Correspondence courses are offered to members.

Training courses become available to equip students for examinations that are currently taken
by over a thousand candidates globally each year.

Rename to The organisation becomes the Lifting Equipment

1988 LEEA Engineers Association (LEEA).

The Association’s name changed for a third time to the Lifting Equipment Engineers
Association. This reflected the far wider range of activities our member companies were
involved in.

LOLER Lifting Operations and Lifting Equipment Regulations

1998 Introduced (LOLER) are introduced in Great Britain.

The introduction of the Lifting Operations and Lifting Equipment Regulations (LOLER)
significantly impacted the industry, necessitating a complete overhaul of LEEA’s training,
qualifications, and publications. LEEA’s training, support and guidance grew in importance for
members who needed to adhere to these new regulations. With no sector-specific health and
safety legislation elsewhere, numerous global companies adopted LOLER as a best practice,
thereby increasing the value of LEEA membership.

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Brief History | History of LEEA

Audits for Membership audits are introduced, helping to better

2004 Standards members and raise standards.

LiftEx The first LiftEx event is launched in Birmingham,

2006 Launches offering a platform for the lifting industry.

Accredited The Accredited Training Scheme is introduced to ensure

2008 Training high-quality training for members.

The Registration Scheme is introduced for lifting

Registration equipment inspectors. At the same time overseas
2009 Scheme
instructor-led training begins with the first course help
Launched
in Singapore.

TEAM Card registration and identity scheme for qualified engineers and technicians was
introduced.

Opening in Huntingdon, the centre provides near-live

LEEA Centre of
2010 Excellence training environments with state of the art teaching
facilities.

Membership LEEA achieves a 50:50 split between UK and overseas

2011 Split members.

E-Learning The LEEA E-Learning Academy is launched, making

2015 Academy training more accessible and affordable.

1000
2016 Members
LEEA reaches the milestone of 1000 members.

LEEA The LEEA Awards begin, helping to recognise and

2018 Awards reward excellence in the industry.

LEEA celebrates its 75th anniversary with a

Parliamentary Reception, launches the Apprenticeship
75th
2019 Anniversary
Standard for Lifting Equipment, develops “Think Lifting”,
and establishes the 75:75 Military Transition project,
training and placing 75 veterans.

Other Key Projects

• Licensed Training Partners:

Using approved training companies to deliver LEEA training globally.

• Accredited Training Scheme:

Accreditation of ‘end-user’/’operator’ training courses provided by LEEA members.

• The Lifting Equipment Technician Apprenticeship:

Currently available in England. LEEA continues to work with other nations to provide similar
apprenticeship schemes and National Occupational Standards.

• Military Transition Scheme:

Supporting our Armed Forces leavers and veterans to transition to our industry.

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Brief History | History of LEEA

• Enhancing the audit process and raising the bar of membership:

Maintaining the highest standards.

• Conducting more training at members’ premises and online:

Increasing capacity and availability of training by offering more virtual classroom courses.

• Technical triage system:

Proactively providing technical information to our members within specified times.

• Update to COPSULE:
‘Code of Practice - Safe Use of Lifting Equipment’ continual updates.

• Hosting more member events.

• Introduction of ‘Chat Bot’ on our website:

Fast, simplified access to technical information.

• Annual LEEA Awards and gala dinner and celebrity host:

Celebrating the very best achievements from within our industry.

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VersionEquipment
Lifting 3 Lifting Equipment
Engineers Engineers
Association Association
| Lifting | Lifting
Standards Standards
Worldwide ™ Worldwide
Version™3

MODULE A

LEEA’s Behaviours
for a Safer
World of Work

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Module A | A.1. Learning Outcomes

WELCOME TO MODULE A

LEEA’s Behaviours For A Safer World Of Work

At the end of this module, we expect that the students will be able to:

• Understand how human behaviours directly relate to accidents in the workplace and how
LEEA’s Behaviours for a Safer World of Work will support the reduction of accidents, injuries
and fatalities in our industry.

ASSESSMENT CRITERIA
At the end of this module you will be able to:

• Identify the types of human error that contribute to workplace accidents.

• Define LEEA’s Behaviours for a Safer World at Work.
• Identify how you may improve on LEEA’s defined behaviours in your work to reduce accidents,
injuries and fatalities.

Note:
We estimate that it will take approximately 45 minutes to complete this module.

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Module A | A.2. Safety, Competence and Professionalism

Safety, Competence and Professionalism

Workplace Accidents
It is said that almost all workplace accidents are a consequence of human action (or lack of
action). Errors and violations are the main factors.

• Error: A human error is an action or decision that was not intended. The action or decision was not
aligned to the accepted standard.

• Violation: To deliberately ignore a rule or procedure. ‘Breaking the rules’.

“ Everyone can make errors no matter how well-trained and motivated

they are. However, the consequences of such human failure in the
workplace can be severe. Analysis of accidents and incidents shows
that human failure contributes to almost all accidents.

HSE (United Kingdom) “

Human Factors: Managing Human Failures

LEEA’s Behaviours for a Safer World of Work are unashamedly and deliberately designed to significantly
impact this alarming statistic by influencing and changing both attitudes and behaviours. Our vision with
these Behaviours for a Safer World of Work is to create a safe environment in the lifting and height safety
industries, resulting in eliminated accidents, injuries and fatalities.

“ By educating, influencing and enabling all stakeholders in our industry

to ensure that best practice becomes everyday practice, we will ensure
that each person goes to work in a safe environment and returns home
to their loved ones and friends, every day.

Lifting Equipment Engineering Association “

LEEA’s Mission Statement

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Module A | A.2. Safety, Competence and Professionalism

LEEA’s Behaviours for a Safer World of Work

In order to combat and improve human behaviour and attitude, LEEA’s new generation of training will always
focus on the following behaviours for a safer world of work: safety, competence and professionalism.

These three behaviours are designed to directly impact the number of workplace accidents in our industry
through human behaviour changes.

• Look after yourself and others: Take care of yourself by ensuring you are healthy,
safe and well, then you will be in a position to help others.
• Follow your training: Apply the learning and instructions gained from your training
Safety to your workplace.
• Speak up: If you spot anything that looks unsafe or incorrect speak up and report
it.

• Know what you can do: Know what you can do taking into account your
knowledge, skills and behaviours.
• Know what you can’t do: Recognise the limits of your capabilities, and if at any
Competence time you do not feel entirely confident to perform a task or make a decision,
ensure that you ask someone for help and support.
• Keep yourself up to date: Commit to continuous learning and development and
stay informed about the latest developments in our industry.

• Diligence: Carry out your work with care by ensuring you don’t cut corners or rush.
• Communication: This is a two-way process. Active listening, embracing feedback
Professionalism and giving clear instructions are key to effective communication.
• Lead by example: Anyone can be a leader. Ensure you set an example for others
to follow (behaviour, attitude, appearance).

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Module A | A.2. Safety, Competence and Professionalism

Key Point:
You are a representative of our professional industry and an ambassador for your company.
You are expected to advocate and demonstrate LEEA’s Behaviours for a Safer World of Work.

Example

Chernobyl Disaster (1986)

Chernobyl Nuclear Power Plant is situated in
Northern Ukraine.

In 1986, a 1000-megawatt reactor exploded

releasing radioactivity across Europe. The
consequences were enormous and resulted in
disastrous environmental and human costs.

The exact causes of the incident have been

subject to much debate, but the primary
investigations cited that plant operators had
deliberately violated systematic and numerous
safety procedures.

Summary
We can look at many examples of accidents where human error has contributed to loss of life
and injuries, but there are many minor accidents and near misses that also involve human errors.
As professionals, we must intervene and stop all potential accidents and near misses before
they occur.

Humans will make mistakes through errors and violations. To change this we need to work on
human behaviours and consequences. For example, would the engineers at Chernobyl have
taken the actions they did if they were aware of the consequences their decisions would cause?
Of course not.

In summary, this course aims to help keep you, your colleagues and others safe at work. LEEA’s
Behaviours for a Safer World of Work provide a framework to support this objective.

“ Safety first is safety always.

Charles M Hayes
Senior Railway Executive
“

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Module A | A.3. Reflective Learning Required Activity
!

As previously established, a sound knowledge and understanding of LEEA’s Behaviours for a Safer World of
Work is one of the ways in which this training can positively influence the safety of workplaces.

Having this in mind, think about your current performance against each of the three behaviours and answer
the questions below.

Type in your answer and select “Submit” to answer each question.

How could you improve how you showcase “Safety” in your day-
to-day job? Give at least one example.

How could you improve how you showcase “Professionalism” in

your day-to-day job? Give at least one example.

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Module A | A.3. Reflective Learning Required Activity
!
How could you improve how you showcase “Competence” in
your day-to-day job? Give at least one example.

Key Point:
Once you have completed this assignment it will be recorded as proof of reflective
learning and you may receive feedback from our tutors from time to time.

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Module A | A.4. Knowledge Check Required Activity
!

If accessing this Course Handbook from a mobile or electronic device, click on the correct
answer and then select “Submit” to send in your response.

If using this Course Handbook in its printed version, simply tick the correct response using a pen.
Then refer back to your answers when it’s time for you to input your responses in the LEEA App.

How many accidents in the workplace are due to human error?

30%

Approximately 60%

Almost all accidents

What are the two primary causes of human error in relation to health and safety incidents?

Qualifications and Experience

Safety and Professionalism

Errors and Violations

In what ways does LEEA work with stakeholders to meet its vision of no accidents, injuries or
fatalities?

Advice, Audit and Supervise

Educate, Influence and Enable

Penalise, Warn and Sanction

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Lifting 3 Lifting Equipment
Engineers Engineers
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Standards Standards
Worldwide ™ Worldwide
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MODULE B

Legislation and
Regulations

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Module B | B.1. Learning Outcomes

WELCOME TO MODULE B

Legislation and Regulations

At the end of this module, we expect that the students will be able to:

• Understand the legal framework for health and safety, as well as the duty holder’s responsibilities.

ASSESSMENT CRITERIA
At the end of this module you will be able to:

• Explain what laws apply to the duty-holder.

• Identify the function of enforcement authorities and their inspectors.
• Identify what authoritative sources of information are available to help duty holders comply
with legislation and regulations.
• Explain the consequences of not effectively managing health and safety at work.

Note:
We estimate that it will take approximately 2 hours and 45 minutes to complete this module.

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Module B | B.2. Legal Systems

Legal Systems
Statutory Law vs. Civil Law
In this section, we will look at the difference between statutory law and civil law.

• Statutory Law: written down and passed by a legislative body, e.g. Government.

• Civil Law: deals with the rights and responsibilities of individuals and organisations towards each other.

Statutory Law

Statutory law is written down and passed by a legislative body, e.g. Government. Legislation can cover
many things, such as Health and Safety, Banking and Finance, Education, Healthcare and many others.

The legislation can be in the form of an:

• Act
• Decree
• Written Law
• Resolution
• Other titles

This can vary depending on the country, for example. These are possible variations in some countries.

Statute Laws are known Statute Laws are known Statute Laws are known
as Acts of Parliament. as Written Laws. as Acts of Congress.

These laws are officially recorded and can be looked up in legal books or codes; for example, in the USA,
the ‘United States Code’ contains all federal statutory laws. In Australia, such books and codes are held in
the ‘Federal Register of Legislation’.

Key Point:
All organisations and workers must comply with these laws which consist of rules, orders,
treaties and regulations.

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Module B | B.2. Legal Systems

Health and Safety Statutory Law Examples:

Health and Safety at Work Health and Occupational Safety Labor Law (Law 12)
Work Act (1974). Safety Act (2011). and Health Act (1970). (2003).

Civil Law

Civil law governs the rights and obligations that individuals and organisations have towards each other.
These rights and duties are established by laws or have evolved through tradition and common practices.

Breaches of rights or obligations (situations where one party’s wrongful actions cause harm or injury to
another) are known as a ‘legal wrongs’ or ‘tort’. One of the most common torts in health and safety cases is
negligence. For example, a car accident caused by careless driving, medical malpractice, and slip and fall
incidents.

When someone believes they have been wronged in civil law, they can file a lawsuit against the responsible
person or organisation, and they can seek compensation and/or other remedies. This includes cases where
they have suffered a ‘loss’ due to the wrongdoing.

In the case of companies being the claimants, they are recognised as the ‘corporate person’, who can also
file a claim and pursue legal action if their rights are violated. Whether the claimant is an individual or a
corporate entity, they are always responsible for initiating legal action themselves.

Differences between statutory and civil law

Aspect Civil Law Statutory Law

Claim against another party (individual/ Legal proceedings started by
Purpose
organisation) enforcing authorities
Insurance Organisations can insure against losses No insurance against penalties
Consequence of Compensation for loss, including legal Punished by fines, imprisonment,
breach costs prohibition, improvement notices
Lower burden: based on the balance of Higher burden: must be beyond all
Burden of Proof reasonable doubt
probabilities
The individual or organisation who has Enforcing authorities initiate legal
Who Initiates Action
been wronged proceedings

35
Module B | B.2. Legal Systems

Enforcement Authorities

Globally, health and safety enforcement agencies typically appoint inspectors who are tasked to inspect
workplaces and investigate accidents and causes of ill health. As a result of their work, organisations and
individuals may be prosecuted under statutory law.

Power of Entry: Enter premises at any time Conduct Interviews: Interview anyone
using police assistance when required, involved and take statements for official
where a dangerous situation is suspected. records.

Prevent Access: Shut down access to

Access to Documents: Inspect all
parts, or all of the areas involved to enable a
documents including books, records,
thorough investigation to take place.
technical files and any other data deemed
relevant.
Seize and Retain Items: Inspectors may
take control and remove any articles or
Conduct Investigations: Investigate substances that are found to be dangerous
thoroughly taking photographs, and to people.
measurements, and creating sketches and
drawings with notes to assist with their Collect Samples: Take samples of
enquiry. substances and articles and dismantle
items to access such samples or articles.

At Turbo Engineering, a forklift truck was carrying a full pallet of paint tins, and one of the forks
snapped.

The load dropped to the floor and created a serious spillage of paint which had to be controlled in the
first instance and then cleaned by a specialist contractor. An employee was injured when she slipped
on the paint spillage resulting in a fracture to their arm.

Important facts to notice:

• Some portable electrical tools were damaged beyond repair due to the paint spillage.
• The forklift was found to have been supplied with cracks in one of the forks and this led to its
premature failure.
• It also came to light that Turbo Engineering had not carried out any planned maintenance or
inspections of the forklift.
• No risk assessments had been carried out for forklift operations or control and transportation of
hazardous substances, including spillage containment.

36
Module B | B.2. Legal Systems Required Activity
!
Considering this scenario, there have been breaches of law which are either statutory or civil. Your task is
to identify which of these laws apply to the breaches.

Read each statement carefully, and select the correct answer depending on the statement applying to
civil or statutory law.

The employee tripped on paint spillage and broke her arm as a consequence of her fall.

Civil Law

Statutory Law

Both of the above

The forklift is supplied with existing defects of cracks in the fork.

Civil Law

Statutory Law

Both of the above

Maintenance and inspections had not been carried out on the forklift since it had been purchased by
Turbo Engineering.

Civil Law

Statutory Law

Both of the above

Risk assessment had not been carried out for forklift operations or control and transportation of
hazardous substances, including spillage containment.

Civil Law

Statutory Law

Both of the above

37
Module B | B.2. Legal Systems Required Activity
!
Turbo Engineering wishes to recover costs for the damaged portable electrical equipment.

Civil Law

Statutory Law

Both of the above

38
Module B | B.3. Regulations

Regulations
Regulations
A regulation is a rule or directive made and maintained by an authority, such as a government
agency, to control or govern behaviour, practices, or procedures within specific areas.

There are many sets of regulations applying to health and safety. Other regulations apply to places of work
and some are specific to industries, operations, substances, materials or premises.

Breaking these rules can lead to penalties, fines, or other legal consequences.

Regulations are like the rules of the game, ensuring everyone plays fair and stays safe.

General Employer Duties

Employers, as duty holders, must comply with both national and international laws regarding health and
safety. International laws are outlined by the International Labour Organisation (ILO) through conventions
and regulations for its 187 member states.

“ Each member country shall, in the light of national conditions and

practice, and consultation with the most representative organisations of
employers and workers, formulate, implement and periodically review
a coherent national policy on occupational safety, occupational health
and the working environment.

ILO Convention - C155 “

“ The enforcement of laws and regulations concerning occupational

safety and health and the working environment shall be secured by
an adequate and appropriate system of inspection. The enforcement
system shall provide for adequate penalties for violations of the laws
and regulations.

ILO Convention - C155

“
39
Module B | B.3. Regulations

The ILO Occupational Safety and Health Recommendation R164 of 1981 provides specific recommendations
for actions to be taken by duty holders in particular areas of work. For example, Section 3 (D) covers the
design, construction, use and maintenance.

It also covers testing, and inspection of machinery and equipment liable to present hazards, as well as their
approval and transfer.

Section 3 (F) covers handling, stacking and storage of loads and materials, manually or mechanically.

Member countries must issue or approve regulations, codes of practice or other suitable provisions on
occupational safety and health and the working environment.

Remember LEEA’s Behaviours for a Safer World of Work. Within the value of safety, you should aways:

• Follow your training

• Look after yourself and others
• Speak up and report it

40
Module B | B.4. Duty Holders

Duty Holders
Duty Holders
Duty holders are formed by both organisations and workers who are responsible for ensuring
rules and standards are followed. They both have specific roles to ensure that everything is
done properly and legally, protecting both people and the environment.

Top Level Duty Holders

The Organisation
The legal entity or registered name of the Company, i.e. the Employer, such as Osprey Lifting and Turbo
Engineering. The organisation needs to establish a health and safety policy that is much more than a
document – it should be an integral part of your organisation’s culture, values and performance standards.

The Board
They should set the direction for effective health and safety management and check that suitable
arrangements are in place.

CEO and Executive Directors

They must develop/oversee policies to avoid health and safety problems and must respond quickly when
difficulties arise or new risks are introduced; non-executives must make sure that health and safety are
properly addressed.

Managers and Supervisors

They play critical roles in maintaining a safe working environment and safeguarding all employees. Their
duties are both proactive and reactive, ensuring that health and safety policies are implemented and that
risks are minimised through supervising, consulting, informing and checking. Some of their duties include:

• Developing, implementing and enforcing safety policies

• Maintaining health and safety documentation and reports
• Investigating accidents at work
• Allocating training and education resources
• Managing breaches of health and safety
• Developing emergency plans and procedures

All Other Workers

They have a duty to take care of themselves and others and cooperate with the organisation’s health and
safety arrangements.

41
Module B | B.4. Duty Holders

Leading Health and Safety: A

Framework for Success

Effective health and safety management starts with strong leadership and active involvement at all levels of
an organisation. Achieving a safe workplace requires a collaborative approach where leaders, workers, and
systems work together seamlessly. The key components of a successful health and safety strategy include:

Strong and active leadership from the top:

• Visible, active commitment from the board
• Establishing effective downward communication systems and management structures
• Integration of good health and safety management with business decisions

Worker Involvement:
• Engaging the workforce in the promotion and achievement of safe and healthy condition
• Effective upward communication
• Providing high-quality training

Assessment and Review:

• Identifying and managing health and safety risks
• Accessing (and following) competent advice
• Monitoring, reporting and reviewing performance

Other Duty Holders Within an Organisation

Both the organisation and the worker have a lawful duty of care to each other and to other workers. This
includes exercising reasonable care in order to protect others from the risks of foreseeable injury, health
problems or death at work.

• Organisations must provide a safe working environment and follow health and safety regulations.

• Workers must fully comply with all health and safety arrangements.

Laws require duty holders to carry out specific tasks related to health and safety. If duty holders lack
the necessary skills, they can appoint qualified individuals or organisations to perform these tasks on
their behalf. However, even when tasks are delegated, the duty holder remains responsible for ensuring
everything is done correctly.

Anyone tasked with these responsibilities must be suitably qualified, experienced, and trained — in other
words, they must be competent.

Key Point:
Responsibilities are placed on suppliers and users to ensure lifting equipment and operations
are safe and protect everyone’s health. This is done by making sure the equipment is properly
designed, built, maintained, and used correctly.

42
Module B | B.4. Duty Holders

Key Point:
National legislation and specific international conventions require that anyone undertaking a
duty holder task is suitably and sufficiently trained in health and safety matters, and is informed
of all measures that the organisation has taken to protect all workers and the related policies.

Furthermore, duty holders should inform their supervisor if they become aware of any situation
that presents a danger to life or health.

Remember LEEA’s Behaviours for a Safer World of Work. Within the value of competence, you should aways:

• Know what you can do

• Keep yourself up to date
• Know what you can’t do

43
Module B | B.5. Consequences of Not Managing Health and Safety

Consequences of Not Managing

Health and Safety
The Meaning of Consequences
Consequences are the outcomes or results that follow our actions or decisions.

These are sometimes difficult to realise and understand, and it is often the case that negative
impacts are the main focus of poorly managed health and safety management.

Negative consequences of poorly managed health and safety will of course have detrimental impacts in
many areas for businesses which we will look at, however, effectively managed health and safety can also
result in a positive impact for businesses which have proven track records in keeping people, plant and
premises safe, for example, this may provide a commercial advantage over competitors and recognition for
awards, etc.

“ Health and safety at work is not only a sound economic policy; it is a

basic human right.

Kofi Annan “
UN Secretary General (1997-2006)

Negative Consequences of NOT

Managing Health and Safety

• Injuries and Illnesses: Employees may suffer from accidents, injuries, and work-
related illnesses. This can include anything from minor cuts and bruises to
serious injuries such as fractures, burns, or even life-threatening conditions.

• Fatalities: In the worst-case scenarios, poor health and safety management can
lead to fatalities. Workplace accidents can have devastating effects on families
Human and communities.
Consequences
• Long-term Health Issues: Chronic exposure to hazardous substances or unsafe
working conditions can lead to long-term health problems such as respiratory
issues, hearing loss, or musculoskeletal disorders.

• Mental Health: Poor safety standards can lead to stress, anxiety, and other
mental health issues among employees, reducing their overall well-being.

44
Module B | B.5. Consequences of Not Managing Health and Safety

• Regulatory Penalties: Organisations may face fines and penalties from

regulatory bodies for non-compliance with health and safety laws and
regulations.

• Lawsuits: Injured employees or their families may file lawsuits against the
Legal
organisation, leading to significant legal costs and potential compensation pay-
Consequences
outs.

• Criminal Charges: In extreme cases, company executives or managers may

face criminal charges if negligence is proven to have led to serious injury or
death.

• Increased Costs: Organisations may incur increased costs related to medical

expenses, workers’ compensation, and insurance premiums.

• Lost Productivity: Injuries and illnesses can result in absenteeism, reduced

Financial productivity, and disruptions to business operations.
Consequences • Damage to Equipment: Poor safety practices can lead to damage to machinery,
equipment, and property, necessitating costly repairs or replacements.

• Regulatory Fines: Fines for health and safety violations can be substantial,
impacting the company’s financial stability.

• Damage to Reputation: Organisations known for poor health and safety

practices can suffer reputational damage, leading to a loss of business,
Reputational customers, and potential partners.
Consequences
• Negative Publicity: Media coverage of workplace accidents can tarnish an
organisation’s public image, affecting its brand and market position.

• Disruption of Business Activities: Accidents and unsafe conditions can disrupt

normal business operations, causing delays and affecting the overall efficiency
Operational of the workplace.
Consequences
• Staff Turnover: High rates of injuries and illnesses can lead to increased staff
turnover, as employees seek safer working environments. This can result in
additional costs for recruiting and training new employees.

• Employee Morale: Poor health and safety management can lead to low
Moral and employee morale and job satisfaction, as workers feel undervalued and unsafe.
Ethical • Corporate Responsibility: Organisations have a moral and ethical obligation
Consequences to provide a safe working environment. Failure to do so can undermine their
integrity and ethical standards.

“ The safety of the people shall be the highest law.

Marcus Tullius Cisero “

Roman Statesmen, Scholar, and Writer

45
Module B | B.5. Consequences of Not Managing Health and Safety

My name is Mike Menditt and I work at Turbo Engineering as the Engineering

Manager. I am the company’s appointed person for all operations on site.

Most people call me dodgy Dan! I work at Turbo Engineering

as a Technician. I am currently being trained to become an
appointed person for lifting operations in the workshop, but
it’s not going too well at the moment. We’ve had a couple of
dropped loads and I always seem to get the blame.

Turbo Engineering is loading a tractor onto their trailer for return transportation to their client after
being serviced at their workshop.

Mike Menditt (Engineering Manager) is in charge of the lifting operation. On the previous day, he asked
Danny Danger (Technician) to carry out a pre-use inspection of the crane to ensure that all functions
were available and working correctly, including emergency stop buttons and any other safety features,
and to provide him with a written report following the checks.

On the day of the lift, Mike is operating the crane and Danny is providing hand signals to Mike to guide
the tractor safely onto the trailer.

As the tractor is being lowered onto the trailer it suddenly drops onto the trailer and lands with a
loud impact. The trailer has sustained damage to its base and the crane hook, lifting beam and chain
slings attached to it have crashed into the top of the tractor cabin, breaking glass cabin windows and
causing further damage as it landed.

46
Module B | B.6. Reflective Learning Required Activity
!
Reflective Learning
Establishing the Cause of the Accident
This incident was reported to the relevant enforcing authority who attended site to investigate
the causes.

Following the investigation, issues were raised by the enforcement agency to Tracey Turbo (Managing
Director). The report highlighted:

• Competence of Duty Holders

• Failure to effectively maintain lifting appliances

The investigation had revealed that Mike Menditt said he had asked Danny Danger to carry out a pre-use
inspection of the crane and provide him with a report as soon as he had completed the task.

Danny Danger said that when he operated the crane the hoist brake was a bit noisy, so he climbed the
access ladder to the crane and changed the hoist brake settings until the noise disappeared when he
operated it.

He assumed he had done a good job and prevented an issue from occurring. He included this in his report
to Mike Menditt which was sent by email on completion of his checks.

Breaches
The enforcement authority issued an Improvement Notice against Turbo Engineering as a result
of the following breaches of legislation:

1. Failure to Provide Adequate Training and Supervision for Crane Inspections:

The organisation had failed in its duty to provide suitable and sufficient training to Danny Danger who was
asked to carry out the pre-use inspections of the crane and report on its condition. There were no records
of training, information, instruction or supervision for Danny whilst performing this task.

2. Negligence in Reviewing Safety Reports Prior to Lifting Operations:

Mike Menditt did not access and read the report that Danny had emailed to him on the completion of his
operational checks and proceeded with the lifting operation regardless. Mike failed in his duty to protect
the health and safety of himself and others by not performing his duty with the due diligence necessary to
mitigate risks.

3. Absence of Established Lift Plan and Risk Assessment:

An established lift plan and risk assessment were not available for the lifting operation that took place.

4. Inadequate Training for Working at Height Operations:

Danny Danger accessed the crane which became a working-at-height situation. Again, Danny had not been
trained for this duty.

5. Lack of Maintenance Program and Record-Keeping for Crane Safety:

There was no evidence of an established maintenance programme for the cranes on site and no record of
the last maintenance or thorough examinations carried out.

47
Module B | B.6. Reflective Learning Required Activity
!
Consequence

Turbo Engineering has been given 28 days to implement all preventative and corrective actions, after which
they will be re-visited by the enforcement agency. In addition to this, they now face a fine, based on their
organisation’s turnover, of up to 1.2 million pounds.

Tracey Turbo has now contacted a LEEA member (Osprey Lifting) for their specialist advice and
recommendations moving forward. She asked them where she could source best practice advice for
carrying our pre-use inspections to their cranes on site as she wanted to ensure this information was made
available immediately to Mike Menditt and his staff.

Tracey was advised to download a copy of LEEA’s COSPULE and go to section 2.9 Inspection and
Maintenance (2.9.1 Pre-Use Inspection) for this information in the first instance.

If you are accessing the Course Handbook through a mobile device, you can select the Download
Resource button below to access a digital copy of LEEA’s COPSULE file. Alternatively, access the
equivalent section in the elearning course, or ask your trainer for a copy.

Legislation and Regulations

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

As we know, the organisation (employer) must provide a safe working

environment and follow health and safety regulations at all times. In
what ways did Turbo Engineering fail in its duty holder responsibilities?

48
Module B | B.6. Reflective Learning Required Activity
!
What possible consequences do Turbo Engineering now face
as a result of their health and safety legislation breaches, other
than a large fine?

Remember LEEA’s Behaviours for a Safer World of Work.

Which of LEEA’s Behaviours for a Safer World of Work did Mike

Menditt breach when he asked Danny to carry out the crane
operational checks?

Which of LEEA’s Behaviours for a Safer World of Work did Danny

Danger breach when he changed the hoist brake settings?

49
Module B | B.6. Reflective Learning Required Activity
!
When questioned by the enforcement authority about how their organisation
manages health and safety at work, Tracy Turbo did not understand what
was being asked of her. She said that whilst she had ultimate accountability,
all workers had a part to play and that everyone was equally responsible for
health and safety matters. What does Tracey mean when she said that all
workers have an equal responsibility for health and safety matters?

50
Module B | B.7. Standards

Standards
Standards
Standards are published specifications that set a common language and contain a technical
specification or other precise criteria.

They are:

• Designed to be used consistently, as a rule, a guideline, or a definition.

• Applied to many materials, products, methods and services helping to make life simpler and increase
the reliability and effectiveness of goods and services.
• Designed for voluntary use and does not impose any regulations, but many have such recognition that
compliance with them gives a presumption of conformity.

Quasi-Legal
Quasi-legal describes situations, rules, or decisions that aren’t fully legal but have some legal-
like influence or authority.

They operate in areas where formal laws may not fully apply, providing guidance and structure but they do
not have formal legal recognition.

An example here could be a professional body that can issue licences and enforce standards in professions
like medicine or law, acting with legal-like authority but not as a government agency.

Turbo Engineering holds a library of standards at their premises which is maintained and kept current by
Karen Keeper (Purchasing Manager). These include design and manufacturing standards and safe use and
selection of types of equipment.

They are available digitally for staff to reference when required and centrally controlled by Karen to ensure
only current and valid standards are available.

Various standards are used at Turbo Engineering as they service a global market. These include but are not
limited to:

• ISO (International Organisation for Standardisation)

• EN (European)
• AS (Australian Standards)
• ASME (American Standard of Mechanical Engineers)

51
Module B | B.8. Codes of Practice

Codes of Practice
Codes of Practice
A Code of Practice is a set of written rules which explain how people working in a particular
profession should perform a particular job. There are various types of Codes of Practice:

• ACoP (Approved Code of Practice)

• RCoP (Recommended Code of Practice)
• A trade or professional Code of Practice
• Technical publications
• Safety information sheets

The regulations which provide detailed requirements in respect of the

general duties do not specify how employers and others should meet
those requirements.

This is the role of the Approved Codes of Practice (ACoPs). These

detail how to comply with the legal requirements. ACoPs are produced
by regulatory authorities.

RCoPs (Recommended Code of Practice) are usually acknowledged

and sometimes endorsed by regulatory authorities within a specific
industry or profession.

An example of a Recommended Code of Practice would be LEEA’s

COPSULE (Code of Practice for the Safe Use of Lifting Equipment).

If you are accessing the Course Handbook through a mobile device,

you can select the Download Resource buttonon the right to access a
digital copy of LEEA’s COPSULE file.

You will refer to it throughout this course. Alternatively, access the

equivalent section in the elearning course, or ask your trainer for a
copy.

How do Codes of Practice help us in our work?

52
Module B | B.9. Guidance

Guidance
Guidance
Guidance documents are official publications from government agencies, organisations, or
authoritative bodies. They offer instructions, recommendations and supporting information to
help people and organisations follow laws, regulations, or industry standards.

Guidance documents are not legally binding but they help

to clarify rules and offer best practices.

LEEA (along with many other trade associations) has

produced a range of Guidance documents for its members
which are available at the link below.

Key Point:
Have a look at ‘Chain for Lifting Purposes’ on Page 23. Under the heading ‘Description’, you will
note that only specific lengths of chain link are allowable for chains used for lifting purposes.

Osprey Lifting holds a library of LEEA Guidance documents for their reference. These include:

• LEEA 032 (Guidance on Written Schemes of Examination for Lifting Equipment V2 .1- July 2023)
• LEEA 052 (Guidance on the testing of hand operated lifting machines - Version 3 - August 2021)
• LEEA 059-1 (Guidance to documentation and marking - Part 1 (Manual Lifting Machines) - Version 4 -
November 2022)

If you are accessing the Course Handbook through a mobile device, you can select the Download
Resource button below to access a digital copy of LEEA’s Guidance document, which Osprey Lifting LTD
has access to. Alternatively, access the equivalent section in the elearning course, or ask your trainer for a
copy.

Please take this opportunity to look at the document and the valuable information it provides. It is a pictorial
guide to various types of lifting equipment and the relevant international standards that apply.

53
Module B | B.10 Best Practice

Best Practice
Best Practice
Best practice is usually the standard that good companies choose and therefore these exist as
internal standards within organisations.

Best practices are the most effective and efficient ways of doing things, based on experience and research.

Using best practices helps people and organisations get the best results and avoid common problems.

Regulations, standards and codes of practice are at the core of best practice. Best practice is then elevated
to even higher standards by including methods that have been tried, tested, and proven to work well.

Key Aspects of Best Practice

1. Proven Success:
Best practices are typically backed by evidence and have a track record of successful implementation.

2. Benchmarking:
They serve as benchmarks against which other methods or practices can be measured.

3. Continuous Improvement:
Best practices are not static; they evolve through continuous improvement and adaptation to new
circumstances and innovations.

4. Replicability:
They can be reliably replicated across different settings and contexts to achieve similar results.

5. Efficiency and Effectiveness:

Best practices are designed to maximize efficiency and effectiveness, ensuring that resources are used
optimally to achieve desired outcomes.

54
Module B | B.11. Knowledge Checks Required Activity
!

If accessing this Course Handbook from a mobile or electronic device, simply click on the correct
answer.

If using this Course Handbook in its printed version, simply tick the correct response using a pen.
Then refer back to your answers when it’s time for you to input your responses in the LEEA App.

Which of the following are powers of enforcement authority inspectors?

Gain access to the premises with police assistance

Terminate the employment of the Managing Director

Inspect any documents and relevant data

Interview and take statements from people involved

Remove and organisation’s quality management certification

Close access to premise or equipment to enable investigation

Primary legislation (statutory law) is written and passed by which of the following:

Duty Holders

Legislative Bodies

Health and Safety Enforcement Agencies

55
Module B | B.11. Knowledge Checks Required Activity
!
If a duty holder does not have the skills to perform a specific task and therefore delegate the
task to a competent person, who is responsible for making sure that the work is carried out
safely and correctly?

The duty holders

The delegated competent person

The duty holder’s health and safety consultant

Which of the following documents might Turbo Engineering hold in its standards library?

Recommended Code of Practice for Safe Use of Welding Equipment

Health and Safety Act

Specifications for design of towed agricultural machinery

Which of the following publications would assist a company in performing a particular job in a
specific profession? Select all that apply.

Primary legislation

Codes of Practice

Benchmark data

Best practices are a means of helping businesses to conduct areas of their work effectively
and efficiently. On what basis are best practices formed?

Approval from a legislative body

Experience and research

Trial and error

56
Module B | B.11. Knowledge Checks Required Activity
!
In accordance with LEEA Guidance document 060, which of the following is the only type
of chain to be used for lifting purposes? (Please refer to your downloaded LEEA Guidance
document 060 from section B.9.)

Short Link

Long Link

Medium Link

In which recommended Code of Practice would a user of lifting equipment find information
regarding their duties?

LEEA’s COPSULE

LEEA Guidance Document 060

Statute Law

57
MODULE C

Managing Risks

58
58
58
Module C | C.1. Learning Outcomes

WELCOME TO MODULE C

Managing Risk
At the end of this module, we expect that the students will be able to:

• Understand the risk assessment process and how it contributes to managing risks in the
workplace.

ASSESSMENT CRITERIA
At the end of this module you will be able to:

• Identify the different types of risk assessment and their uses in the workplace.
• Identify hazards and risks in the workplace using a risk assessment template.
• Identify the correct control measures needed to reduce risks to safe levels.
• Explain how a risk assessment is applied and monitored in the workplace.

Note:
We estimate that it will take approximately 2 hours and 15 minutes to complete this module.

59
Module C | C.2. Primary Reasons for Risk Assessment

Primary Reasons for Risk Assessment

Definition of Risk Assessment
Risk assessments are designed to assess the hazards at work and then help to reduce the risk
from them to a safe level. There are legal requirements for completing risk assessments.

There are different types of risk assessments commonly used in the workplace.

• General Risk Assessment: Designed to assess hazards and risks of an area or activity and apply
controls. E.g. Store room risk assessment.

• Specialist Risk Assessment: Designed to focus on a specific hazard and assess the risk and controls.
E.g. Noise risk assessment, and manual handling risk assessment. These are often used when a general
risk assessment highlights a concern that needs further investigation.

• Dynamic Risk Assessment: Dynamic risk assessments are used when something unexpected happens.
They are principally the same in that they look for hazards, risks and controls but are usually simpler and
easier to complete as there may be an urgent need to complete. E.g. a crane accidently drops its load
and now the workers must safely clean it up. Before they do, they will use a dynamic risk assessment.

Each of the risk assessments mentioned above is designed to identify the risk from hazards at work and
then suggest appropriate controls to reduce the risk to a safe level.

The output from a risk assessment is to communicate the key elements (hazards and controls) to those who
could be affected by the risk. This is often done using a set of safe work instructions commonly known as a
safe system of work or method statement.

There are various ways of communicating safe work instructions. They could be:

Principally, as long as all people who could be affected by the hazards are made aware of those hazards
and the necessary controls then it should meet legal requirements.

For the remainder of this course we will use a ‘General risk assessment’ as an example.

If you are accessing the Course Handbook through a mobile device, you can select the Download
Resource button below to access more information on Managing Risks and Risk Assessments at Work.
Alternatively, access the equivalent section in the elearning course, or ask your trainer for a copy.

60
Module C | C.3. Common Workplace Hazards

Common Workplace Hazards

Understanding Hazards in the Workplace
A hazard refers to anything that has the potential to cause harm, injury, illness, or damage in
the workplace. Hazards can take many forms, from physical objects and unsafe conditions to
chemical, biological, or ergonomic factors. Identifying and understanding these hazards is a
critical part of ensuring workplace safety, as it allows organisations to implement controls and
preventive measures to mitigate risks.

• Hazard: Something with the potential to cause harm or an adverse effect.

• Risk: Likelihood of harm or adverse effect to occur and how serious its consequence could be.

Key Point:
Although a hazard can be anything with the potential to cause harm, only those hazards that are
likely to do so should be included in a risk assessment.

Example

A ballpoint pen would not need to be included in a general risk assessment for an office. However, if the pen
was on a manufacturing site where titanium is used, pens might be banned as precaution. That’s because
there is a risk of the tungsten in the ballpoint pen getting into the titanium and contaminating the finished
product. This would affect its strength and could cause a metal failure when in use.

The hazard (pen) stayed the same but the risk (likelihood and consequence) changed when we moved from
an office to a manufacturing site.

An employee at Osprey Lifting has recently been involved in an accident on-site. An extension lead
was left trailing across the floor, unattended. As a result, he tripped over the extension lead and
sustained injuries to his head, right elbow and both hands.

61
Module C | C.3. Common Workplace Hazards

If accessing this Course Handbook from a mobile or electronic device, simply click on the correct
answer.

If using this Course Handbook in its printed version, simply tick the correct response using a pen.
Then refer back to your answers when it’s time for you to input your responses in the LEEA App.

What is the hazard in this situation?

The extension lead

The employee

Both of the above

What is the risk?

The likelihood and consequences of the employee being harmed

The potential to cause harm

The effect (severity of injuries sustained)

“ A risk is the likelihood that a hazard will actually cause its adverse
effects, together with a measure of the effect. It is a two-part concept
and you have to have both parts to make sense of it. Likelihoods can
be expressed as probabilities or in a qualitative way. The effect can be
described in many different ways.

HSE (United Kingdom)

Definition of a risk
“

62
Module C | C.3. Common Workplace Hazards

Common Hazards in the Lifting Industry

63
Module C | C.4. Control Measures

Control Measures
Applying the Hierarchy of Controls in Risk Assessment
The Hierarchy of Controls offers a structured approach to managing workplace risks by
prioritising the most effective control measures. In risk assessments, it helps ensure that
hazards are addressed in the most efficient way, starting with elimination and moving down to
less effective methods like PPE. This section explains how to apply each level of the hierarchy
when assessing and controlling risks.

Study the diagram below showing the control measures hierarchy used to determine what controls
should be used.

In the first instance, we should ask whether we can:

1. Eliminate the hazard entirely.

2. If this isn’t possible, how can we ensure that the risk of harm is reduced to a minimum level.

The hierarchy of control measures is used to manage workplace risks effectively. They can include:

• Redesigning the Job: Modify tasks or roles to eliminate or reduce hazards, making them safer.

• Replacing Materials, Machinery, or Process: Substitute hazardous materials or equipment with safer
alternatives to minimise risk.

• Organising Work to Reduce Exposure: Change workflows, schedules, or layouts to minimize workers’
exposure to risks.

• Implementing Practical Safety Measures: Identify necessary controls like safety barriers, ventilation, or
procedures that make the work environment safer.

64
Module C | C.4. Control Measures Required Activity
!
• Providing Personal Protective Equipment (PPE): Ensure workers have appropriate PPE, and emphasise
consistent use to protect against remaining hazards after other controls are in place.

This hierarchy emphasises that eliminating or reducing hazards at the source (job design, substitution) is
preferable before relying on PPE, which should be the last line of defence.

The illustration below shows a snapshot of Turbo Engineering’s workshop. There are several hazards to
be seen.

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

List the hazards below together with the most effective control
measures you would use for each of them.

Did you consider alternatives to PPE or was this your safe choice? Can
you be certain a simple, cost effective control doesn’t exist higher up
the hierarchy? Do you feel confident it is now safe?

65
Module C | C.5. Reflective Learning Required Activity
!

The illustration below shows a snapshot of Osprey’s Lifting. There are several hazards to be seen.

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

Taking a look at the illustration above, identify as many hazards as

you can. Type the hazards you have spotted into the box below, and
alongside each of them, state who or what may be harmed by the
hazard. Note: Remember that hazards should have a realistic chance of
causing harm or an adverse effect.

66
Module C | C.6. The Five Steps to Risk Assessment

The Five Steps to Risk Assessment

Carrying Out a Risk Assessment
An accepted method for carrying out a risk assessment is to follow five key steps.

STEP 1 - Identify the Hazards:

This should be a list of hazards that have a foreseeable chance of causing harm and/or an
adverse effect.

STEP 2 - Assess the Risks:

Assess the risk by considering who might be harmed and how. What existing controls do we
currently have?

STEP 3 - Control the Risks:

Control the risk. Are we happy with the current level of control or do we need more? If we do
need additional controls what are they? Who will implement it? When will it be complete?

STEP 4 - Record your Findings:

Record your findings using your company approved template and ensure you share the
document with other workers either directly or in the form of safe work instructions.

STEP 5 - Review the Controls:

Periodically review the controls e.g. 12 months or after any changes that impact the risk
assessment. E.g. new equipment, change to a process, etc.

Example Template for a Risk Assessment

67
Module C | C.7. Reflective Learning Required Activity
!

Mike Menditt is carrying out maintenance on an overhead travelling crane (bridge crane). He
recognises the work requires him to work at height but will access the crane using a mobile elevated
work platform (access platform) as shown below:

Mike will be working from the access platform basket and will have a small set of hand tools with him,
including a 500ml tin of lubricant, wire brush and cleaning cloths.

The crane is parked in the middle of the factory bay and workers will be able to walk underneath as
Mike is working above.

Other important factors to have in mind:

• Another crane is operating on the same track but the operators have been asked to stay away from the
crane where Mike is working. As the power cannot be isolated, Mike will be working on a ‘live’ crane that
has electrical power available.

• It has been a while since Mike operated this access platform but he is confident of his ability to operate
it safely. Unfortunately, there are no other staff available to assist Mike at this time whilst he is working
on the crane.

• The workshop is very noisy at the moment due to the large amount of fabrication work that is being
carried out.

68
Module C | C.7. Reflective Learning Required Activity
!

Managing Risks

STEP 1 - If accessing the Course Handbook through a mobile device, simply select Download Resource
button below to access an empty template for a Risk Assessment. Alternatively, ask your trainer for a
copy.

STEP 2 - Fill in and save your Risk Assessment.

• Identify the hazards present in the situation described above.

• Assess their risk to people, plants, and premises.
• State what suitable controls you would put in place for each of them.

STEP 3 - If accessing the Course Handbook through a mobile device, upload your completed Risk
Assessment using the button below. Alternatively, keep hold of it and access the online version of the
course through the LEEA App to complete this activity.

This will take you to a third party window (Jotform) where you will be asked to upload your file.

69
Module C | C.7. Reflective Learning Required Activity
!

Crossword

We have put together a crossword to help you reinforce what you have learned so far. The clues are all
available from your learning this far into the course. The solution will be provided to you later.

70
Module C | C.8. Knowledge Check Required Activity
!

If accessing this Course Handbook from a mobile or electronic device, simply click on the correct
answer.

If using this Course Handbook in its printed version, simply tick the correct response using a pen.
Then refer back to your answers when it’s time for you to input your responses in the LEEA App.

Managing risks in the workplace starts with which of the following?

Ensuring first aid and medical facilities are available

Risk assessment

Issuing PPE to all workers

When following the 5 steps to risk assessment, once the hazards have been identified,
and associated risks have been assessed and controlled, what final step is necessary to
complete the process?

Issue PPE to all workers directly involved

Record the findings and review the controls

Hold a tool-box talk to explain the risk assessment

A type of risk assessment that focuses on a specific hazard, assessing the risks and
controls is known as:

Hazard perception

Risk management

Specialist risk assessment

71
Module C | C.8. Knowledge Check Required Activity
!
In the process of controlling risks, what is the most effective method?

Eliminate the risk

PPE

Substitution

What hazards should be included in a risk assessment?

Only hazards that could cause fatality

Potential hazards likely to cause harm to people or damage to equipment and property

Only hazards with a potential to cause damage to equipment and property

72
MODULE D

Industry Relevant
Definitions

73
73
Module D | D.1. Learning Outcomes

WELCOME TO MODULE D

Industry Relevant Definitions

At the end of this module, we expect that the students will be able to:

• Understand definitions and key terms commonly used in the lifting equipment industry and
their application.

ASSESSMENT CRITERIA
At the end of this module you will be able to:

• Understand the definition and attributes of the competent person.

• Understand different categories of lifting equipment.
• Explain terms used in regard to the mechanics and operation of lifting equipment.
• Define safety-related terms used in lifting equipment.
• Explain the requirements for inspection and examination of lifting equipment.
• Identify documentation and records that must accompany inspections and their importance
for compliance and traceability.

Note:
We estimate that it will take approximately 2 hours and 25 minutes to complete this module.

74
Module D | D.2. Competent Person

Competent Person
Competent Person
The term ‘Competent Person’ has been used in various legislation around the world for a long
time.

Current legislation uses the term for a variety of duties to describe a person with the
necessary attributes:

• Skills
• Knowledge
• Attitude
• Training
• Experience (to perform the specific duty to which the requirement refers)

There can therefore be several ‘Competent People’, each with their own duties and
responsibilities, i.e. competent for the purpose.

I am Richie Right. I work at Osprey Lifting as a Senior Lifting Equipment

Technician. I have completed the LEEA Foundation Certificate and hold
LEEA diplomas for Lifting Accessories, Manual and Powered Machines,
Bridge and Gantry Cranes, and Supporting Structures.
I have been in the Lifting Equipment Industry for over 12 years, and I
have attended many other training courses in Working at Height, Risk
Assessment and Powered Access Equipment Operations.

Attitude

• Richy is committed to LEEA’s Behaviours for a Safer World of Work and holds regular short training
sessions with other team members to promote their importance and explain how following them will
help to eliminate human errors and violations.

• Richy actively seeks continuous improvement in his role and researches new topics to enrich his
knowledge. He keeps himself current with the very latest information from the lifting equipment industry
and LEEA.

• Richy’s appraisal records commend how he regularly receives good feedback from his customers when
working on their site. Customers say that Richy is respectful, courteous and very helpful.

75
Module D | D.2. Competent Person

76
Module D | D.2. Competent Person

Think back to the incident that took place earlier where the tractor dropped onto the trailer.

Danny Danger had tampered with the crane’s hoist brake but was not competent to have done so. Why?

Danny did not have the ability to adjust the brake. He had no skills, had received no training and no
information was provided to him. He certainly wasn’t experienced in this type of work. Danny broke several
of LEEA’s Behaviours for a Safer World of Work on that occasion.

The Competent Person should have the maturity to seek such specialist advice and assistance as may
be required to enable him/her to make necessary judgements and be a sound judge of the extent to
which he/she can accept the supporting opinions of other specialists.

For example, the competent person inspecting, maintaining or examining lifting equipment must be
able to certify with confidence whether it is free from defect and suitable in every way for the duty the
equipment is required.

77
Module D | D.3. Reflective Learning Required Activity
!

As a result of the dropped tractor incident we looked at, Danny Danger has been prohibited from
carrying out any operational checks of all cranes at Turbo Engineering until he has been trained and
deemed competent to do so.

The organisation was at fault on this occasion as suitable and sufficient training had not been provided
to the workers.

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

As a duty holder to carry out the operational checks of cranes, in addition to

appropriate knowledge, what other key areas of competency would you expect
Danny to be able to demonstrate? Give examples for each of your answers.

Being competent doesn’t mean you know everything. If Danny is

unsure about the work he is carrying out, what sources of information
are available to him and where might he find them?

If after further training, Danny is still unsure and needs further guidance, which of LEEA’s
Behaviours for a Safer World of Work would this action be most closely aligned to?

Competence

Safety

Professionalism

78
Module D | D.4. Common Units of Measure

Common Units of Measure

Common Units of Measure
A unit of measure is a standard way to describe how much of something there is.

For example, we use metres to tell how long something is, kilograms (kg) to tell how heavy
something is, and seconds (s) to tell how long something takes.

Using units of measure helps everyone understand and compare amounts clearly.

Different systems of units are based on different choices of a set of fundamental units. The most widely
used system of units is the International System of Units, or ‘SI’. There are seven SI base units. All other SI
units can be derived from these base units.

“ The Safe Working Load, Rated Capacity or Maximum Lifting Load of new
equipment will be in metric units of tonnes (t) or kilograms (kg) or imperial
units of Tons (T) and Pounds (lb). The generally accepted rule is that a
Safe Working Load, Rated Capacity or Maximum Lifting Load of less than
one tonne or Ton are marked in kilograms or pounds respectively.

Lifting Equipment Engineering Association “

COPSULE s1.6.1.5

Under the SI system when marking lifting equipment only one decimal point is used for fractions of a tonne
e.g. 2.1t, apart from when marking 0.25 which is always to two decimal places, e.g. 2.1t, 2.2t, 2.25t, 2.3t,
2.4t, 2.5t, 2.6t, 2.7t, 2.8t, 2.9t.

Whilst it is largely accepted that this format is used in the lifting equipment industry, LEEA is not aware
of any documented guidance to support this. Therefore, this information is provided as a supplement to
general marking requirements only.

Key Point:
Some products are still manufactured with the WLL marked in hundredweights (CWTs).
Few people are now familiar with these units so, to avoid possible confusion, LEEA strongly
recommends that such products are re-marked in the weights and measures system of the
country of use.

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Module D | D.4. Common Units of Measure

• Ton (US) ‘T’

T = Imperial or US Ton. 1 Ton (US) = 2000lbs = 907.185kg = 0.907t (metric) (commonly referred to as the
‘short Ton’).

• tonne (metric) ‘t’

t = metric tonne. 1 tonne (metric) = 1000kg = 2204.62lbs (rounded to 2204lbs)

• Ton (Imperial) ‘T’

1 Ton (imperial) = 1016kg = 2239.9lbs (rounded to 2240lbs) (‘long Ton’ in the USA)

• Hundredweight ‘CWT’
The hundredweight is an old imperial measurement system in which 1 Ton is divided into 20
subdivisions, each being a hundredweight.
Occasionally, lifting accessories may be found in service today with a marked safe working load or
working load limit of ‘cwt’. 1 hundredweight (cwt) = 50 kg, therefore, a marked load limit of 2 Ton 1 cwt =
2050kg, rounded down to 2t.

80
Module D | D.5. Lifting Equipment Categories, Assessories and Applicances

Lifting Equipment Categories, Accessories

and Appliances: Definitions
Lifting Equipment Categories
There are three categories of lifting equipment to be aware of:

• Lifting Equipment : A Generic term covering lifting accessories and lifting appliances.

• Lifting Appliances: Any machine which can raise, lower or suspend a load but excluding machines
incorporating a guided load (i.e. lifts) and continuous mechanical handling devices (i.e. conveyors). Also
commonly referred to as lifting devices. Lifting appliance chains and wire rope hoists.

• Lifting Accessories: An accessory, or accessory for lifting, is used to define an item of equipment used
to attach the load to the lifting appliance. Such equipment is also known as ‘rigging equipment’, ‘lifting
gear’ or ‘lifting tackle’ and includes chain, wire rope or textile slings, shackles, and eyebolts, etc.

Example of Lifting Appliance (Electric Chain Hoist)

Example of Lifting Accessory (Chain Slings)

81
Module D | D.6. Effect of Working Angles

Effects of Working Angles

Effect of Working Angles
When multi-leg slings are used at angles, the load in the individual sling legs will increase as the
angle of each leg to the vertical (including the angle between the sling legs) becomes greater.

In the application below, the 2-leg sling is connected to the load at two points, with the angle from the
vertical to the leg of each sling being approximately 40 degrees.

• The vertical and horizontal loadings result in the force within the sling legs (shown by the arrows in the
illustration below).

• The greater the angle from the vertical to the sling leg, the higher the force (tension) will be in the sling
legs.

In some places, the tension in the sling legs is calculated using the angle between the two sling legs, called
the included angle. In other places, they use the angle between the sling leg and the ground (horizontal
plane) to find the tension.

No matter which method is used—whether it’s the angle between the legs, the angle from the sling to the
vertical, or from the sling to the horizontal—the calculated load on each sling leg will always be the same.

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Module D | D.6. Effect of Working Angles

Using the angle between the legs of a sling as an example, we can see how the greater the angle, the
greater the tension in each leg.

The illustration above shows the effect of loading on the sling legs for a 1-tonne load being lifted at
various angles. Once the angle exceeds 120 degrees, the load on each sling leg increases dramatically and
overloading of the sling will occur.

For this reason, the maximum slinging angle is 120 degrees (included angle) or 60 degrees (from the
vertical).

It is industry best practice to use a maximum slinging angle of 90 degrees (included angle) or 45 degrees
(from the vertical) as the sling is being used under its maximum capacity.

Take a look at the illustration below which shows a worker at Turbo Engineering holding two heavy
buckets in his arms.

His arms are feeling the load of each bucket directly downwards as they hang from his hands.

The larger the angle between the worker’s arms, the more the load will increase in each arm. Looking at the
sling angle diagram above, the bucket test demonstrates how the stress in each sling leg amplifies as the
angle between the legs increases.

83
Module D | D.7. Single and Multi-Purpose Equipment

Single and Multi-Purpose Equipment

Single-Purpuse Equipment
This equipment is any equipment designed for and dedicated to lifting a specific load in a
specified manner or working in a particular environment, i.e. used for a single purpose.

The illustration below shows a ‘drum lifter’ in operation. The drum lifter is a lifting accessory that is designed
to lift and handle metal drums which normally contain either loose granular materials or liquids.

Because the drum lifter can only be used for this purpose, it is classified as single-purpose lifting
equipment.

Multiple-Purpuse Equipment
Multipurpose equipment is any equipment designed to a standard specification to lift a variety
of loads up to the marked SWL, i.e. used for general (multi) purposes, and not designed for one
specific lifting application.

A chain sling is a good example of multi-purpose lifting equipment.

84
Module D | D.8. Minimum Breaking Load (MBL)

Minimum Breaking Load (MBL)

The Minimum Breaking Load (MBL)
This is the calculated load below which an item of lifting equipment will not break or
fail due to distortion.

The illustration below shows a bottom hook from a lever hoist that has been severely overloaded in service,
but although it has deformed, it did not break.

From this value we can calculate the WLL (Working Load Limit) using the designated FoS (Factor of Safety)
for a particular piece of lifting equipment.

85
Module D | D.9. Factor of Safety

Factor of Safety
Factor of Safety
The Factor of Safety (FoS), also known as the safety factor or working coefficient, is vitally
important in the engineering and design of lifting equipment.

A chain sling is a good example of multi-purpose lifting equipment.

It is a factor which is applied to the Minimum Breaking Load (MBL) to determine the Working Load Limit
(WLL).

The Factor of Safety varies with the product to take account of the susceptibility to damage and considers
the type of stresses the item will meet in normal use.

The Factor of Safety also ensures that lifting equipment can withstand loads and stresses beyond the
expected operational limits.

The Factor of Safety is normally provided in the standard which the item of lifting equipment is being
manufactured in accordance with.

Think of the consequences of not having a Factor of Safety built into lifting equipment design. For example,
there would be no tolerance for loss of material and strength due to wear in chain or wire rope slings in
service. This wear will increase the risk of sling failure during normal service.

In summary, we can say that within defined limits, the Factor of Safety allows for wear and tear to lifting
equipment in service (usually this limit is between 8% and 10% reduction in its cross-sectional area).

86
Module D | D.10. Working Load Limit (WLL)

Working Load Limit (WLL)

Working Load Limit (WLL)
This is the maximum load (mass) that an item of lifting equipment is designed to raise, lower
or suspend.

In some standards and documents, the WLL is referred to as ‘maximum SWL.’ This term is
more generally used for lifting accessories, but lifting appliances are now commonly marked
with a ‘rated capacity’.

A chain sling is a good example of multi-purpose lifting equipment.

Example

The image below shows a textile round sling. The label on this sling indicates a Working Load Limit (WLL) of
3 tonnes (3t), meaning it is designed to lift up to 3 tonnes safely.

For this type of sling, the required Factor of Safety (FoS) is 7:1. The sling must withstand at least 7 times
its WLL in testing. To verify its safety, the manufacturer tests the sling to confirm it can handle a Minimum
Breaking Load (MBL) of:

3t (WLL) × 7 (FoS) = 21t (MBL)

This test ensures that even at 21 tonnes, the sling should not break, though it may become deformed.

When the sling is used for its intended load of 3 tonnes, it has a built-in safety margin 7 times greater than
the load it lifts (7:1 Factor of Safety).

87
Module D | D.10. Working Load Limit (WLL) Required Activity
!

We have now discovered the direct relationship between:

• MBL (Minimum Breaking Load)

• FoS (Factor of Safety)
• WLL (Working Load Limit)

Reflect about what you have learned throughout this section, then select the correct answer.

If a item of lifting equipment has a FoS of 5:1, and a WLL of 2t. what is the MBL?

10t

8t

20t

If an item of lifting equipment has a WLL of 3t and an MBL of 15t, what is the FoS?

2:1

5:1

10:1

If an item of lifting equipment has a MBL of 30t and a FoS of 6:1, what is the WLL?

2t

20t

5t

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Module D | D.11. Safe Working Load (SWL)

Safe Working Load (SWL)

Safe Working Load (SWL)
The safe working load or specific application load (SWL) is the maximum load (mass) as
assessed by a Competent Person which an item of lifting equipment may raise, lower or
suspend under particular service conditions.

The SWL is marked on lifting equipment and is provided in all legally required documentation
for each piece of equipment.

A chain sling is a good example of multi-purpose lifting equipment.

Key Point:
Under particular conditions defined by the competent person, the SWL may be less than the
WLL.

An example of this is provided in the case study given in the ‘Rated Capacity’ section.

The SWL will normally be the same value as the working load limit, maximum safe working load or rated
capacity. In some geographical regions the word ‘safe’ is not used in the description but the requirement is
the same, so instead of safe, the phrase ‘specific application’ is used instead.

89
Module D | D.12. Hazardous Duties

Hazardous Duties
Sometimes, it is important to reduce the working limit of lifting equipment because of dangerous conditions.
These conditions can include:

• Extreme temperatures
• Strong winds
• High-risk lifting situations where there might be sudden loads or inaccuracy of weights involved

When these situations happen, safety measures must be put in place to stop the lifting equipment from
being used at its full capacity.

90
Module D | D.13. Rated Capacity

Rated Capacity
Rated Capacity
This is defined as the maximum gross load that the lifting appliance can lift in any given
configuration; generally used for lifting appliances in the same way as the Working Load Limit
is used for lifting accessories.

A chain sling is a good example of multi-purpose lifting equipment.

Example
The illustration below shows the hook block
assembly of a bridge crane marked with its
rated capacity. This would also appear on
the crane structure itself.

There is often confusion between the terms

SWL (Safe Working Load), working load
limit, and rated capacity.

To explain, the working load limit or rated

capacity refers to the maximum load a piece
of equipment can safely handle under ideal
conditions. In most cases, this is the same
as the SWL.

However, if the conditions of use are less

than ideal, a competent person may need
to lower the SWL to ensure safety. In these
situations, the SWL will be lower than the
working load limit or rated capacity.

An Osprey Lifting customer has a bridge crane rated at 10t Rated Capacity. This is the maximum safe
working load that the crane can lift under ideal conditions. Due to the crane being used on an outdoor
supporting structure, exposed to occasional high wind speeds, a risk assessment was carried out and
the competent person decided that this should be reduced accordingly.

• The 10t Rated Capacity was reduced to 7t SWL (safe working load), 3t less than its rated capacity.

• A load limiter was fitted by Osprey Lifting to prevent the crane from being used at its full capacity and
set to 7t SWL.

• The crane was re-marked with the reduced SWL accordingly, both on the crane and the hook block
assembly.

91
Module D | D.14. Inspection and Examination

Inspection and Examination

Inspection
There are three levels of inspection and examination which are designed to ensure the safety of
equipment, i.e. pre-use inspection, interim inspection and thorough examination. In some regions, these
are known by different titles, but in effect, they do the same job.

Pre-use Inspection

Normally completed by the operator of the equipment before each use and in accordance with the
manufacturer’s instructions.

This is a basic check for obvious signs of damage before the equipment is used and is vitally important
to the safety of the planned lifting operation.

Typically, the operator will be looking for damage such as dents to protective cases, permanent
deformations, abnormal noises, oil leaks from machinery, markings that are correct and present etc. Any
such findings should be reported to inspection or maintenance personnel.

Key Point:
If equipment is provided ‘ready to use’ in the lifting equipment stores which is then found to
have damage or other identified issues such as no markings, then this may be indicative of poor
management of lifting equipment as it should not have been ready for use.

Post-use checks should also be carried out by operators as best practice before lifting equipment
is returned to storage as it may have been damaged during use. This should be identified so that the
equipment is not made readily available for other users without necessary repairs/replacement.

Interim Inspection

The interim inspection, also referred to as frequent inspection, is the second level of inspection. The nature
and extent of the inspections are derived from a risk assessment.

Interim inspections focus on critical components identified in the risk assessment that may become a
danger before the next periodic thorough inspection (examination).

The number and frequency of these inspections are also determined by the risk assessment and the
manufacturer’s literature.

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Module D | D.14. Inspection and Examination

Thorough Examination

Also known as periodic inspection or thorough inspection, the thorough examination is a visual
examination of the lifting equipment carried out by a Competent Person carefully and critically and, where
appropriate, supplemented by other means such as measurement and testing in order to check whether the
equipment is safe to use.

It is also used as a check of the suitability of the equipment and the inspection/maintenance regime. This
means that a thorough examination should not find any defect affecting the safety of the equipment. If it
does, this would suggest that there is an issue with the inspection/maintenance regime, the competency of
the inspectors or maintainers, the product’s fitness for purpose, etc.

Summary
In summary, the thorough examination is a safety net, used to identify inadequacies in the
inspection/maintenance regime and thereby provide a means of improvement and prevent
recurrence.

This means the root cause of any defect found following a thorough examination should be investigated and
rectified with appropriate measures to prevent reoccurrence.

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Module D | D.15. The Report of Thorough Examination

Report of Thorough Examination

Report of Thorough Examination
On completion of the thorough examination by a Competent Person, a Report of Thorough
Examination should be issued. This should be kept with the equipment records.

A Report of Thorough Examination (also known as a report of thorough inspection or report of periodic
inspection) is a report issued by the Competent Person giving the results of the thorough examination,
which will detail the defects found or include a statement that the item is fit for continued use.

Where the Competent Person has carried out a test as part of the inspection/examination, the report will
also contain details of the test.

Key Point:
The Report of Thorough Examination must be retained as part of the lifting equipment
records. In some cases, a reference to the test report appears as an appendix to the thorough
examination.

Additional Resource

LEEA has published several Report of Thorough Examination templates which are available on our website
accessible from the link below.
www.leeaint.com.

They are available for the various grades of membership and include single and multiple-item templates.

Select the links below to download examples of reports used in thorough examinations.

Ref_05_LEEA_030_Certificate_Of_Thorough_Examination.pdf

Ref_06_LEEA_030_Certificate_Of_Thorough_Examination_Multiple_Items.pdf

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Module D | D.16. Reflective Learning Required Activity
!

In the Managing Risk module, we looked at the dropped load incident where the crane hoist brake
failed and the tractor was dropped onto the trailer bed.

Tracey Turbo has set a corrective action for Mike Menditt who is required to establish an inspection
and examination programme for the cranes, using Osprey Lifting for advice and guidance.

Having firstly made a recommendation to Tracey, Mike has asked Osprey Lifting to ensure that all
lifting equipment on site is covered by the inspection programme, not just the cranes.

If accessing the Course Handbook from a mobile device, simply select the Download Resource button
below to have a digital copy of the Recommendation Letter from Osprey Lifting LTD to Turbo Engineering
LTD. Alternatively, you can access the relevant section within the online version of the course at the LEEA
App, or contact your trainer.

Industry Relevant Definitions

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

Tracey Turbo asked Mike Menditt to establish an inspection and examination

programme for the cranes on-site at Turbo Engineering. Mike made a
recommendation to Tracey to include all lifting equipment on site, and their
service/transportation vehicles before approaching Osprey Lifting for their
recommendations. What would Mike have included in his recommendation to
Tracey and why?

95
Module D | D.16. Reflective Learning Required Activity
!
Osprey Lifting have advised PRE-USE and INTERIM checks be carried out on all
lifting equipment. Explain what is meant by the different types of inspection.

What are the 5 different attributes that Mike will need to consider for any of
his staff selected to carry out either pre-use or interim inspections? List the 5
attributes and give an example for each.

Why do you think Osprey Lifting have recommended that they carry out
Thorough Examinations of all lifting equipment?

What is the difference between lifting accessories and lifting appliances referred
to in the recommendation?

Osprey Lifting will issue the Reports of Thorough Examination on completion of

the work. What is the purpose of this report? What information would you expect
to be included in these reports?

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Module D | D.16. Reflective Learning Required Activity
!
Are there any other considerations Mike should take into account before
establishing the agreement for Thorough Examinations to be carried out by
Osprey Lifting?

97
Module D | D.17. Knowledge Check Required Activity
!

If accessing this Course Handbook from a mobile or electronic device, simply click on the correct
answer.

If using this Course Handbook in its printed version, simply tick the correct response using a pen.
Then refer back to your answers when it’s time for you to input your responses in the LEEA App.

Which of the following is a valid reason for a Factor of Safety to be designed into
lifting equipment?

Manufacturers can demand a higher price for their products

The FOS allows for wear and tear to lifting equipment in service

The FOS allows for intentional overloading from time to time

Which of the following is the correct classification for a 2-leg wire rope sling?

Lifting accessory

Lifting appliance

Single-purpose equipment

Which of the following is the correct term for the load below which an item of lifting
equipment will not break or fail due to distortion?

WLL

SWL

MBL

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Module D | D.17. Knowledge Check Required Activity
!
Which of the following types of lifting equipment inspections have their frequency
determined by risk assessment and the manufacturer’s literature?

Pre-use

Thorough examination

Interim

As the angle between the two legs of a sling increases, what is the effect on each leg of the sling?

The stress in each sling leg decreases

Each leg of the sling will be affected by increased stress

The stress in each leg of the sling will remain constant

What is the most widely used system of measures used in the lifting equipment industry
in current times?

Imperial System

International System

US System

Where would you be the most likely to find the term ‘Rated Capacity’ used on lifting
equipment?

Chain Sling

Powered Hoist

Drum Lifter

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Module D | D.17. Knowledge Check Required Activity
!
The Working Load Limit (WLL) is calculated by using the Minimum Breaking Load (MBL) and
which of the following?

Rated Capacity

Factor of Safety

Safe Working Load

Following a thorough examination, the competent person will issue which of the following
documents?

Though Pre-Use Inspection Report

Report of Interim Inspection

Report of Thorough Examination

100
Version 3
Lifting Equipment
Lifting
Engineers
Equipment
Association
Engineers| Lifting
Association
Standards
| Lifting
Worldwide
Standards Version
™ Worldwide ™3

MODULE E

Manufacturing
of Lifting
Equipment

101
101
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Module E | E.1. Learning Outcomes

WELCOME TO MODULE E

Manufacturing of Lifting Equipment

At the end of this module, we expect that the students will be able to:

• Understand the duties and responsibilities of the lifting equipment manufacturer in the
process of placing an item of lifting equipment into the marketplace.

ASSESSMENT CRITERIA
At the end of this module you will be able to:

• Identify the duties of a lifting equipment manufacturer.

• Explain how relevant safety regulations and standards apply to lifting equipment.
• Identify the types of documentation required for traceability of products, including design
specifications, test and inspection records.
• Explain what documents and information should be provided by the manufacturer for the end
user.
• Explain why records should be kept for compliance and auditing requirements.

Note:
We estimate that it will take approximately 1 hour and 50 minutes to complete this module.

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Module E | E.2. Duties of the Manufacturer

Duties of the Manufacturer

Duties of the Manufacturer
There are numerous national legislative requirements worldwide concerning the supply and
use of lifting equipment.

A manufacturer can be any natural or legal person who designs and/or manufactures lifting
equipment or partly completed lifting equipment and is responsible for its conformity with
the applicable legal requirements before it is placed on the market under his own name or
trademark or for his own use.

In the absence of a manufacturer as defined above, any natural or legal person who places the equipment
on the market or puts it into service shall be considered a manufacturer.

• Manufacturer: Someone who makes a product available in a specific country

• Importer: Someone outside of an organisation who makes a product available
• Distributor: Any seller of equipment other than the importer

Key Point:
Assembler: A company assembling a lifting accessory such as a chain sling from components
becomes the ‘manufacturer’ of the finished sling and therefore bears the same responsibilities as
the manufacturer for issuing the necessary documentation with the product(s).

Manufacturers must compile all information relating to the products they place into the market for future
reference and traceability purposes. This is know as the ‘Technical File’.

Examples of information that should be included in the Technical File are:

• Design documentation (drawings, calculations etc)

• Research papers
• Standards used
• Welding, electrical and other specifications
• Testing requirements
• Material certificates
• Records of materials used in the manufacture of the end product and their traceability documents
• Any other information relating to the lifting equipment manufacturing process

Safety Requirements

Examples of Legislation and Standards

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Module E | E.2. Duties of the Manufacturer

Manufacturers must meet strict safety requirements for lifting equipment, which are laid out in applicable
legislation and standards. These are designed to ensure that lifting equipment is manufactured and used
safely to prevent accidents, injuries and fatalities.

These legislations and standards can vary depending on the country or region of application. Below you
can find a range of examples of how safety regulations and standards apply to lifting equipment in some
regions, including International (ISO) standards.

OSHA (Occupational Safety and Health Administration

United States of America
Standard 29 CFR 1910.179 (Overhead Travelling Cranes) covers specific safety requirements for overhead
and gantry cranes used in industries. It mandates regular inspections, safe working practices, operator
training, and proper load handling.

LOLER (Lifting Operations and Lifting Equipment Regulations)

United Kingdom
This regulation covers multiple areas including thorough examinations and inspections, markings, record
keeping, suitability and maintenance, competencies etc.

EN Standards
European Union
EN144492-2 (Power-driven winches and hoists) covers safety rules for the operation and construction of
winches and hoists, ensuring they meet requirements for load capacity and mechanical safety.

AS Standards
Australia
Australian Standards set out technical specifications and guidelines to ensure that lifting equipment is safe
to use and maintained correctly.

For example, standard AS 1418.1 – General Requirements sets out general safety requirements applicable to
all cranes, hoists, and winches. Part 1 sets out general safety requirements applicable to all cranes, hoists,
and winches.

ISO Standards
International
ISO 4301-1 (Cranes - Specification) specifies classification systems for the different types of cranes based
on their loads, usage, and operational environment. It helps operators and companies select the right crane
for the task to avoid overuse and unsafe conditions.

Compliance

Manufacturers of lifting equipment are required by regulations to integrate high safety standards into their
products. They must comply with all applicable national supply legislation. This legislation varies between
countries worldwide, but its fundamental principles generally align with ISO 12100: The safety of machinery,
general principles for design, risk assessment, and risk reduction.

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Module E | E.2. Duties of the Manufacturer

Their responsibilities include the following:

• Ensuring the equipment is safe and suitable for its intended purpose
• Providing detailed information on proper use, as well as potential misuse, including guidelines for
inspection and rejection
• Ensuring compliance with all relevant health and safety regulations applicable to the region
• Carrying out the necessary testing and verification of the equipment
• Supplying end users with comprehensive safety information
• Offering guidance to ensure safe usage and maintenance
• Highlighting any foreseeable hazards associated with the equipment

Instructions for Use

Modern supply legislation, industry standards, and specific technical requirements from LEEA all emphasise
the necessity of providing appropriate instructions for use with all lifting equipment.

Manufacturers of lifting equipment must ensure that instructions for use are supplied with the
equipment placed on the market.

This can be done in either of the following ways:

1. A signed Manufacturer’s Certificate and regional conformity document can be included in the
instructions for use, or;

2. A document showing the contents of the Manufacturer’s Certificate and regional conformity
document (not necessarily including the serial number and the signature) may be included
in the instruction booklet. In this case, the Manufacturer’s certificate and regional conformity
documentation must be provided separately.

These requirements are in place to ensure safety, proper use, and compliance with legal frameworks. Here
are some key points regarding these instructions:

• Contents must cover the intended use of the lifting equipment but also any potential misuse.

• Instructions are to be laid out in a manner that takes into account the general educational level of
the expected equipment operators.

If accessing the Course Handbook from a mobile device, simply select the Download Resource
button below to have a digital copy of of the LEEA_062 Guidance Document providing details of how
manufacturers are to develop instructions for use to accompany their products. Alternatively, you can
access the relevant section within the online version of the course at the LEEA App, or contact your trainer.

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Module E | E.2. Duties of the Manufacturer

Remember LEEA’s Behaviours for a Safer World of Work, particularly the value of professionalism.

• Diligence: Carry out your work carefully by ensuring you don’t cut corners or rush.

• Communication: It’s a two-way process. Actively listen and embrace feedback. Give clear instructions.

• Lead by example: Anyone can be a leader. Ensure you set an example for others (behaviour, attitude,
appearance).

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Module E | E.3. Verification and Load Testing

Verification and Load Testing

Verification of New Equipment
The verification methods used by the manufacturer will depend on the standard being
worked to.

• New Equipment: New equipment should comply with the essential health and safety requirements
stated in the applicable legislation, and the product standard (where available), and should be issued
with the required conformity documentation specified.

• In-service Equipment: Once in service, the verification methods used will be those deemed necessary
by the Competent Person in reaching their conclusions about fitness for purpose.

They should preferably be following the legislation and standards to which the equipment was made. Where
this is not known, a design review would be required.

Some equipment is unsuitable for proof load testing due to the nature of the materials used, e.g. textile
slings. Some items are assembled from components verified to their own standards; no further tests are
therefore required, e.g. grade 8 mechanically assembled chain slings.

Key Point:
In some countries, this additional proof load testing is a requirement of their specific standards.

Proof Load Test

A proof or test load is a mass or force applied during testing by a Competent Person. It exceeds the
equipment’s Working Load Limit and is specified in relevant standards, manufacturer guidelines, ILO
(International Labour Organisation) Tables, and COPSULE for various types of lifting equipment.

If a proof test is conducted as part of the examination, this load will be recorded in the thorough
examination report and included on the test certificates.

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Module E | E.4. Conformity and Documentation

Conformity and Documentation

Conformity
Depending on the standard being worked to, the manufacturer will usually issue a:

• Manufacturer’s certificate
• Record of test
• Statement of conformity confirming the verification of the equipment (regional conformity
document)

Statement of Conformity
When Osprey Lifting sells lifting equipment to their customers in the UK, they issue a ‘Declaration’
(Statement) of Conformity which is required by national legislation. Here is an example of the document that
is produced and the information it provides:

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Module E | E.4. Conformity and Documentation

When Osprey Lifting carry out a test for a client, they issue a ‘Record of Test’ only as they are not the
manufacturer of the equipment. An example of this is shown below which is the front cover of the report but
clearly shows the information that is contained within:

Key Point:
A Statement of Conformity is a document that is the manufacturer’s confirmation that any
necessary manufacturing tests or other product verification required by the standard have been
carried out and states the working load limit of the item.

Unless a specific document is required by the national supply legislation, then this document is also known
as the ‘birth certificate’ for the product and it should be retained as part of the lifting equipment records.

Documentation

Operators across the globe place their trust in lifting equipment, so they need assurance that the
equipment supplied meets the required standards and legislation. All lifting equipment should be of
adequate strength, made of sound material, well-constructed, and suitable for the tasks it is designed to
perform. It must also be verified to meet the standards being worked to.

New equipment should comply with essential health and safety requirements as defined by applicable
regional legislation and relevant product standards, where available. It must also be issued with the
necessary conformity documentation.

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Module E | E.4. Conformity and Documentation

In addition, lifting equipment should carry unique identification to ensure:

• Safety: For easy identification during operation.

• Maintenance: To keep track of inspection schedules.
• Regulatory compliance: Ensuring the equipment meets legal requirements.
• Usage tracking: To monitor the equipment’s history, including certifications and inspections.

Manufacturers and suppliers of lifting equipment, as well as inspection services, are often legally required
or bound by product standards to provide the appropriate documentation to their customers. However,
confusion often arises regarding which documents are needed in specific circumstances

Documentation Requirements

Who?
• It should be clear in the documentation who the manufacturer and/or importer/distributors are,
as applicable regulations may define different obligations and responsibilities to these economic
operators.
• In some cases, the involvement of a third party may be required to assess whether the product
conforms to legislation.

What?
• It should be clear in the technical documentation what the equipment type is, its intended use and its
performance (e.g. working load limit).

• To make the declaration of this information easier, most products on the market will have a standard or
technical specification clearly defining these requirements. In this case, the manufacturer can simply
declare compliance with the standard. This reference should be unambiguous and unconditional.

• Some information can be legal and, in that case, it should be clear what legal framework applies. As an
example, simply claiming that a product is CE-marked (in Europe) is not enough. A construction product
may be CE marked under the Construction Products Regulation, machinery may be also CE marked
under the Machinery Regulation.

When?
• The documentation should be issued by the manufacturer as soon as the product is placed on the
market.

Where?
• The documentation should be in line with the legislation of the country where the product was
placed on the market. However, when the product crosses the border to a different country, the
documentation will then have to be in line with the legislation of that country.

• The European Economic Area is an exception to this as it is a single market with free movement of
goods. This means that a product placed on the market and CE marked in any of these countries will be
automatically accepted in any of the other countries.

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Module E | E.4. Conformity and Documentation

Why?
• Documentation is important because it contains the technical information that will allow the user to
safely use the product and claim conformity with the relevant legislation, when relevant.

How?
• It is usually required that relevant information is in an accompanying document. However, technical
information can be quite lengthy and there is a risk that it may be lost or associated with a different
product in the supply chain. To avoid this, manufacturers and legislation are increasingly adopting
digital methods (e.g. QR codes or digital data tags in the product) to improve traceability to the correct
information.

Traceabiility

Both Osprey Lifting and Turbo Engineering keep records of all lifting equipment they own for purposes of
traceability.

Osprey Lifting maintains technical records of its products, including serial numbers and batch number
information.

Serial numbers and batch numbers are provided in the equipment ‘birth certificate’ which is sent to their
customer, Turbo Engineering, and the equipment is also marked with this information.

Turbo Engineering now has traceability of the products they purchase from Osprey Lifting. If there was an
incident or failure of the equipment, Turbo Engineering could provide the documentation and serial numbers
etc to Osprey Lifting who would then be able to investigate that particular product’s technical information.

If Osprey Lifting finds a fault in the item, they may decide to recall all of the items sold, so it’s important that
their records show what was sold and to whom so that they can contact them with a recall notice.

Importance of Keeping Records

The safekeeping of lifting equipment records is vitally important for many reasons. Below are some of the
circumstances in which Turbo Lifting may need to refer to a robust lifting equipment record-keeping system.

Legal Compliance
In many instances, the keeping of lifting equipment records is mandated, and therefore Turbo Engineering
would be legally obligated to keep the records.

These may include:

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Module E | E.4. Conformity and Documentation

• Thorough examination reports

• Equipment maintenance logs
• Operator training certificates

On occasion, these records may be required for inspection by Government agencies or inspection bodies as
proof of compliance to legal obligations.

Safety Management
Proactive maintenance management ensures that lifting equipment is regularly inspected and maintained to
spot potential safety issues before they arise.

An example of this would be when Osprey Lifting inspects the wire ropes fitted to the cranes at Turbo
Engineering; they log the amount of wear and broken wires amongst other things on each inspection visit.

Over a period of time, the detailed records indicate the rate of wear, or number of wire breaks in each wire
rope, enabling Osprey Lifting to use this information and predict a life expectancy for the rope. They can
then replace it before it becomes too late and it breaks in service, preventing both safety and productivity
issues for Turbo Engineering.

These records may also be used if ever there was an accident associated with the equipment as they would
provide a thorough history of the maintenance, inspection and repairs, assisting with any investigation
matters.

Insurance
Insurance companies will expect to see documented evidence of maintenance, repairs and inspection to
validate any claims that may be submitted.

Well kept records will demonstrate that Turbo Lifting’s lifting equipment has been taken care of in a
responsible manner and maintained in a safe working condition.

Legal Protection
Should there be an accident or failure of the lifting equipment, documented evidence of good maintenance
and inspection of their lifting equipment will help to protect Turbo Engineering from legal prosecution or
claims, showing that all the equipment meets the regulatory requirements.

Training and Competency of Operators

Turbo Engineering should keep records of personnel training, qualifications and competencies for using
different types of lifting equipment.

This should be backed-up with refresher training requirements with a schedule to ensure this is not missed.

Cost Efficiency
Turbo Engineering have proven that preventative maintenance and timely replacement of lifting equipment
and certain components saves them time in lost production (down-time) and expensive repair costs should
the equipment fail in service.

An example of this would be where the storeman at Turbo Engineering (Steve Stockton) keeps spare wire
ropes for all of the bridge and gantry cranes that are regularly used in service. When Osprey Lifting advise

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Module E | E.4. Conformity and Documentation

the replacement of a wire rope, they are able to do so immediately, preventing breakage of the rope in
service or damage to other components. This also prevents down-time and maintains productivity as the
crane is not left out of action whilst a new wire rope is sourced and delivered to site for fitting.

Osprey Lifting manufactures the CH2 Electric Chain Hoist.

With each hoist they put into the market, their comprehensive Owners Manual is included, together with the
Declaration (Statement) of Conformity:

We can see extracts from the Owners Manual in the images below:

113
Module E | E.5. Reflective Learning Required Activity
!

I am Simon Teck, and I am an Engineer at Turbo Engineering. My work is

mainly in the area of Facilities Management on-site, ensuring the service
lines of all of the assets they need to get work done on time with minimal
downtime for services, tools and equipment.

Turbo Engineering has had another incident involving a dropped load. The incident was a near-miss
and no one was harmed.

Some paint damage was caused to the workshop floor but otherwise, everything was undamaged.
A 2-leg chain sling was suspended from the bridge crane hook and connected to a block of steel that
was fitted with hoist rings.

The weight of the steel block was unknown but estimated at 2t by Simon Teck who was overseeing
the lift.

During the lift, the load dropped and crashed to the floor. An internal investigation was carried out to
establish the cause of the accident.

Results of the Investigation

• The chain sling did not have any markings to identify its identity or supporting records.

• The chain sling was made from a master link, chain couplers (connectors), 2 lengths of chain and two
hooks to terminate the sling, each made by a different manufacturer.

• During the interview, Simon Teck said he had produced the chain sling using scrap chain slings that had
been cut up and put in the scrap bin.

• He had cut the chain to length from two different scrapped slings and took the master link and hooks
from other slings, selecting what he thought looked ok for the job.

• Simon said it was important for the sling to be put together quickly as he was under pressure from the
production line to get the job done on time and they had no other suitable lifting equipment available.
If he hadn’t done so, the company would not have gotten the job done and would have faced delay
penalties from their customer.

• The sling in question had no paperwork or documents supporting its origin and conformity.

• The chain leg angles were established as being 70 degrees to the vertical during the lift.

114
Module E | E.5. Reflective Learning Required Activity
!

Manufacturing of Lifting Equipment

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

Given the results of the investigation, which of LEEA’s Behaviours for a Safer
World of Work had Simon Teck breached when he undertook the construction of
the chain sling and put it into service?

Turbo Engineering is clearly the ‘manufacturer’ of this chain sling. What duties of
the manufacturer have been breached, and why?

It was fortunate that no one was harmed on this occasion, but if they had, what
possible consequences would Turbo Engineering and Simon Teck face?

Was the angle of the slings correct for the 2-leg lift? Please explain your answer.

115
Module E | E.6. Knowledge Check Required Activity
!

If accessing this Course Handbook from a mobile or electronic device, click on the correct answer
and then select “Submit” to send in your response.

If using this Course Handbook in its printed version, simply tick the correct response using a pen.
Then refer back to your answers when it’s time for you to input your responses in the LEEA App.

Which of the following best describes the definition of ‘verification’ in relation to the lifting
equipment manufacturing process?

Patenting the design of the product

Procedures to check product meets required standard or specification

Including all necessary paperwork with the product before it is delivered to customer

Which of the following documents might be issued by the manufacturer with all new
lifting equipment?

Report of Thorough Examination

Inspection Report

Manufacturer’s Certificate

Osprey Lifting have an obligation to ensure the lifting equipment products they manufacture
incorporate high safety standards. Which of the following should they follow to ensure this
requirement is met?

LEEA COPSULE

All relevant national supply legislation and standards

Copies of technical drawings used by other companies

116
Module E | E.6. Knowledge Check Required Activity
!
For which of the following reasons would Turbo Engineering keep spare wire ropes for
their most frequently used bridge and gantry cranes?

They buy them when they are at their lowest price to reduce costs

They are instantly available when needed which minimises crane down-time

They can sell them to Osprey Lifting if they need one at another customer’s site

117
MODULE F

Materials and
their Properties

118
118
118
Module F | F.1. Learning Outcomes

WELCOME TO MODULE F

Materials and their Properties

At the end of this module, we expect that the students will be able to:

• Understand the characteristics of a range of materials used in the manufacture of lifting

equipment and how their individual properties affect their application.

ASSESSMENT CRITERIA
At the end of this module you will be able to:

• Recognise the key material characteristics required of materials used in the manufacture of
lifting equipment.
• Explain mechanical properties such as strength, hardness, ductility, toughness, and elasticity
and how these affect lifting equipment in service.
• Explain how the properties of certain materials will influence their application in the work
environment.
• Explain the various forces that act on lifting equipment in service.
• Identify limitations of use for lifting equipment made from a range of materials.

Note:
We estimate that it will take approximately 2 hours and 50 minutes to complete this module.

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Module F | F.2. Characteristics and Forces

Material Characteristics and Forces

Strength ensures the lifting equipment can handle the
Strength
intended weight without failure.

Shock Shock resistance protects the equipment and its operators

Resistance from accidents caused by unexpected loads or impacts.

Ductility ensures the safety, reliability, and longevity of lifting

Ductility equipment, making it a vital property for materials used in
this industry.

Wear Wear resistance ensures the equipment remains functional

Resistance and efficient over time.

Chemical Chemical resistance prevents failure and contamination in

Resistance environments with harsh chemicals.

Resistance to
Resistance to extreme temperatures ensures the equipment
Extremes of
can operate safely and effectively in various environments.
Temperature

Corrosion Corrosion resistance prevents equipment failure and ensures

Resistance safety.

Key Point:
Lifting equipment requires a balance of physical and chemical properties to make it suitable for
its purpose.

Consider the top hook shown in the picture below (left). It has stretched open due to overloading but its
ability to deform in this way without suddenly breaking has prevented a serious incident from taking place.

The same could be said of a chain sling (picture on the right) that is subject to overloading. The links will
stretch and deform giving indication of the problem before breakage occurs.

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Module F | F.2. Characteristics and Forces

Forces

Shear
Shear force is a type of force that causes parts of an object to slide past each other in opposite directions
(opposing forces slicing an object apart).

Imagine holding a piece of paper flat on a table and pushing the top part to the right while holding the
bottom part still; the paper will want to tear or slide. That sliding effect is due to shear force.

The illustration below shows a bolt in shear. As the plates it has bolted together are pulled in opposite
directions, the bolt is placed in shear loading, shown by the red zig-zag line.

Tension
Tension is the force that pulls and stretches an object like a wire rope or chain when lifting a load. If the
tension becomes too great, the chain or wire rope may break under a tensile load.

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Module F | F.2. Characteristics and Forces

Compression
When a material is subjected to compression, it is squeezed. This has the effect of squashing the material
and altering its shape if the load is too great for the material to resist.

Consider a jack being used to lift a heavy load, as shown below. The weight of the load is applying a
compressive force through the jack.

Torsion
Torsion is when an object twists because a force is applied to make it rotate. A good example of torsion is a
drill that is cutting through metal. The drill motor turns the drill so that it can cut through the steel, and the
steel is resisting the drill. In effect, the drill bit is being twisted and is therefore under torsion stress.

122
Module F | F.2. Characteristics and Forces Required Activity
!

Practical Applications

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

In the picture on the right, a bow shackle is being subject to a

bending force at the centre of the shackle pin from the force of
the wire rope, but what type of stress is being applied where
the pin is located in both the eyes of the shackle body?

Tension

Torsion

Shear - Double Shear

In the picture on the right, where the hook is connected to the

shackle body, what type of stress will be applied to the hook?

Compressive and tension

Torsion

Shear

The motor pictured on the right is driving the hoist gear box
of an electric hoist. What stress is placed on the motor’s rotor
when it is driving the gearbox to lift a load?

Tension

Torsion

Compression

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Module F | F.3. Material Properties

Material Properties
Material Properties
The materials used by the lifting equipment manufacturer will need to be strong and capable
of resisting shock loads, but other properties will be required depending on the application.

These are:

• Resistant to wear
• Resistant to chemicals
• Resistant to extreme temperatures
• Resistant to corrosion

Lifting equipment requires a balance of physical and chemical properties to make it suitable for its purpose.

Strength
This is a measure of how well a material can resist being deformed from its original shape. Typically, metals
are specified for their tensile strength or resistance to being pulled apart, but compressive strength is also a
property describing the resistance to being squeezed.

Ductility
Ductility is a physical property of a material that describes its ability to be stretched or deformed without
breaking. A ductile material can be drawn into a wire or elongated in tension.

Ductility is an important factor in lifting equipment manufacture as it determines how materials will behave
under tensile stress.

Malleability
Malleability is a property of materials that allows them to be shaped or moulded without cracking or
breaking. Think of it like how you can shape soft clay into different forms without it falling apart.

These materials can withstand a lot of compressive stress (squeezing forces) without breaking.

Elasticity
The ability of a material to return to its original dimensions after the removal of stress. An example of this
would be a spring.

Brittleness
Brittleness is the tendency of a material to fracture or fail upon the application of a relatively small amount
of force, impact, or shock. Remeber, brittleness is the opposite of toughness.

Plasticity
The ability of a material to retain its new dimensions once the stress is removed. A good example of this is a
stretched chain link.

124
Module F | F.3. Material Properties

Toughness
This is the ability of a material to absorb energy and plastically deform without fracturing.

Imagine a chain sling where the chain had been manufactured to be extremely hard and strong. That would
mean the chain would be brittle and when shock-loaded or overloaded, it could break instantly giving no
warning and releasing the load.

If the chain is tough, it will be less brittle and have an amount of ductility so it will stretch (deform) under
load and give an indication of the problem, allowing it to be withdrawn from service on inspection. The
chain, whilst not as hard and strong, will be tough and able to deform.

Hardness
A measure of how resistant solid matter is to various kinds of permanent shape changes when a
compressive force is applied.

The illustration below shows a selection of steels that have been hardness tested by pressing a test piece
into the metal surface under a known pressure to see how far it penetrates the material. The wider the
penetration area is, the softer the metal.

Corrosion
Corrosion is the process where materials, especially metals, get damaged or deteriorate over time due to a
chemical reaction with their environment.

The most common form of corrosion is rust, which happens when iron or steel reacts with oxygen and
moisture.

125
Module F | F.4. Metals

Metals
Metals
Metals used in the manufacture of lifting equipment are selected for their particular
properties and characteristics.

Cast Iron
The use of cast iron is limited, as it is brittle, but it still has an important role in the manufacture of certain
items of lifting equipment.

• The material has very little shock resistance

• It is however very strong under compression forces

Rope sheaves may be manufactured from cast iron as they are subjected to compressive forces and
therefore have strength in this application.

Steel
Mainly found in the form of carbon steels and alloy steels.

Carbon Steels
Three classes of carbon steels are used in various ways in the manufacture of lifting equipment:

1. Low carbon steels

2. Medium carbon steel
3. High carbon steels

As their names suggest the quantity of carbon affects the tensile strength of the steel.

Alloy Steels
Alloy steels have varying carbon contents but they obtain their properties from the addition of other alloying
elements.

Copper, brass and bronze are used in the manufacture of lifting equipment although this is limited to
specific applications. We’ll look at these in further detail during the LEEA Diploma training courses.

126
Module F | F.4. Metals

Aluminium
Used in several lifting equipment applications.

• Bluish and silvery-white in colour

• Very light, malleable, and ductile with high heat and electrical conductivity
• Good corrosion resistance against certain chemicals and acids
• Low resistance against other elements such as seawater

Commonly used in ferrules which secure the turn-back eye when manufacturing wire rope slings and also
lightweight portable supporting structures (mobile lifting structures) as the illustration shows below.

127
Module F | F.5. Plastics and F.6. Natural Fibres

Plastics
Plastics (Polymers)
Man-made chemical-based materials are used extensively in the manufacture of lifting
equipment, particularly for webbing slings and round slings.

• Good toughness, is very light, has good electrical and thermal insulation and can be easily damaged.

• Corrosion-resistant with selective resistance to various chemicals.

Polyester Polyamide Polypropylene

A New Plastic Material

A newer plastic material is now extensively used in the lifting equipment industry and is called HMPE (High
Modulus Polyethylene) and this offers several advantages over Polyamide, Polypropylene and Polyester.
You will explore this in more depth later in the course.

Natural Fibres
Natural Fibres
Fibre rope slings are a traditional form of textile sling whose origins are recorded in the
earliest history of lifting equipment.

Although their use has declined in recent years in favour of the newer forms of textile slings, i.e. man-made
flat woven webbing slings and round slings, they can still be found in general use throughout the industry.

Natural fibres are produced from grasses and other leaves that are spun to form ropes. Fibre rope slings
are produced from cut lengths of rope which are then hand-spliced. Common natural fibres for rope slings
include:

Manila Hemp Sisal

128
Module F | F.7. Heat Treatment

Heat Treatment
Heat Treatment
Heat treatment is a process used to change the properties of steel and other metals by
heating and cooling them in a controlled way.

This process can make steel stronger, more flexible, or harder depending on the desired
outcome.

Advantages of Heat Treatment

Material properties are important in the lifting equipment industry as they will determine how an item of
equipment will react under stress (loading) conditions.

Heat treatment gives manufacturers the advantages of:

• Enhancing toughness
• Increasing ductility
• Improving strength
• Relieving internal stresses
• Improving a material’s ability to be machined
• Improve wear resistance

In summary, heat treatment is a process that modifies the physical and chemical properties of steel to make
it suitable for lifting equipment applications by changing its hardness, strength, toughness, and ductility.

129
Module F | F.8. Stress and Strain

Stress and Strain

Stress
In the section Characteristics and Forces, we looked at types of external forces (shear,
tension, compression and torsion) that lifting equipment can be subjected to in service.
When a material is subjected to an external force, it can cause deformation in the material
(change of shape). The external force is known as the stress.

Tensile Stress
When a material is stretched from its original length/shape.

Compressive Stress
When a material is squeezed and squashed.

Shear Stress
When a material is subjected to a force that causes it to slice, or slide parallel to the force applied.

Strain
The deformation of a material caused by the application of stress is known as the ‘strain’.
There are no dimensions for the amount of strain.

For example, if a length of wire rope is subjected to excessive tension, it will deform under load and
elongate (stretch from its original length). The difference between the original length of the rope and the
new deformed (stretched) length is the amount of strain.

Key Point:
When a lifting equipment examiner performs an inspection of lifting equipment, deformation due
to overload (strain) is one of the most important checks that will be made.

Another example of a strain is to consider an elastic band.

If it is held at its ends in a relaxed state, it will show no signs of extension, but as stress is applied to
the elastic band between your hands (an opposing force), it will begin to stretch. This amount of stretch
(extension) of the elastic band is known as the strain.

130
Module F | F.9. Reflective Learning Required Activity
!

I am Pete Hammer. I am the Works Engineer at Osprey Lifting Limited.

I am responsible for all engineering matters in our company, including
manufacture, testing, installation, maintenance and inspection services.

Pete Hammer is holding a short training session with his technicians at Osprey Lifting as part of their
ongoing professional development. Pete holds these sessions each month, rotating topics around key
Behaviours for a Safer World of Work: Safety, Competence and Professionalism.

In this session, Pete is focusing on competence. He wants to explain to the team why it is important
that anyone with a duty to inspect lifting equipment understands the importance of a material’s ability
to deform under stress without actually breaking.

Materials and Properties

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

Pete has asked for your advice. What example would you provide for this topic
and what key information would be required to explain this?

131
Module F | F.10. Knowledge Check Required Activity
!

If accessing this Course Handbook from a mobile or electronic device, click on the correct answer
and then select “Submit” to send in your response.

If using this Course Handbook in its printed version, simply tick the correct response using a pen.
Then refer back to your answers when it’s time for you to input your responses in the LEEA App.

What are the two properties of steel that can be changed through heat treatment?

Carbon content and size

Strength and Hardness

Size and iron content

The type of force which considers opposing forces slicing through a material is called?

Shear Force

Compression Force

Torsion Force

Which of the following is a characteristic of cast iron?

It is malleable and easily deformed under stress

It is very strong under compression

It is extremely expensive

What are the 3 main polymers used for the production of webbing slings and round slings?

Polyamide, Polypropylene and Polyester

Sisal, Manila and Polyester

Aluminium weave, Hemp and Kevlar

132
MODULE G

Lifting
Accessories

133
133
Module G | G.1. Learning Outcomes

WELCOME TO MODULE G

Lifting Accessories
At the end of this module, we expect that the students will be able to:

• Identify different types of lifting accessories and understand their functionality, application
and limitations of use.

ASSESSMENT CRITERIA
At the end of this module you will be able to:

• Identify the different types of lifting accessories.

• Explain the differences between accessory grades and finishes.
• Understand the basic methods of use for lifting accessories and their potential misuse.

Note:
We estimate that it will take approximately 2 hours and 50 minutes to complete this module.

134
Module G | G.2. Chain Slings

Chain Slings
Chain Slings
A chain sling is a lifting sling constructed from high-strength steel chains, frequently used in
industrial environments for lifting loads.

They are preferred in situations where the loads are exceptionally heavy, abrasive, hot, or sharp,
as these conditions might compromise the performance or integrity of other types of slings,
such as textiles or fibre rope slings.

Chains are mainly made from alloy steel, of which two types are used in lifting equipment:

• Medium Tolerance
• Fine Tolerance

All chains are calibrated to a degree of accuracy by the manufacturer. The accuracy of calibration depends
on how the chain will be used.

Medium Tolerance

Used to manufacture chain slings.

Medium tolerance chain has to be more ductile as chain slings may be subjected to shock loading. This is
where the load is lifted suddenly and the full load is immediately taken by the legs of the chain sling.

In use, a medium-tolerance chain sling is not subjected to continual wear, so it doesn’t have to be as hard
as the chain used in manual and powered machines. The calibration of the chain is not as critical as that of
the fine tolerance chain as it will not be in contact with moving parts during operational use.

Fine Tolerance

Used in manual and powered hoists, never on chain slings.

Fine tolerance chain is in continual contact with a load wheel inside a manual or powered chain hoist and
therefore it must be harder on its surface to withstand the wear it will be subjected to, and the calibration of
each chain link must be very accurate so that it sits precisely into the chain pockets of a manual or powered
lifting machine load wheel.

135
Module G | G.2. Chain Slings

Key Point:
The hardness of a fine-tolerance chain makes it more brittle (less ductile) and this could be
dangerous if it was used for chain sling manufacture. If shock loading or overload were to occur,
the chain may break in service.

Chain Slings Grades

Most modern chain slings are constructed from grade 8. Grade 10 chain is also becoming increasingly
popular.

The grade number identifies the strength of the chain. Grade 10 is stronger than grade 8. This will be
explored in greater detail during the LEEA Diploma courses.

Chain Slings Assembly

Modern chain slings are assembled from components that have mechanical fixings, such as spiral roll pins,
to retain them. They are therefore assembled and repaired very easily using standardised ranges of fittings.

• A full range of fittings is available with the

‘clevis’ form of chain connection, such as
hooks, shackles and egg links.

• This system of assembly minimises the

number of components necessary to
assemble a sling, as the terminal fittings are
located directly onto the chain.

• With clevis attachment, the end link of the

chain is passed into the jaw of the clevis.

• A load pin is passed through the clevis and

chain, on which the chain seats.

• Spiral roll pins or circlip-type fixings are used

to lock the load pin in position.

The illustration below shows a clevis pin connection to the hooks of the chain sling. In the top right of the
picture, this shows a typical ‘component connector’ which connects the chain to the master link assembly.

The image bon the next page shows the spiral roll pins being fitted to the clevis load pin during assembly.
These retain the load pin to the sling in service.

136
Module G | G.2. Chain Slings Required Activity
!

Please refer to LEEA COSPULE section 1A5.3.

If you haven’t yet downloaded COPSULE you will find the link in section C ‘Codes of Practice’.

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

What three main principles/factors should be made when selecting slings for
lifting operations?

There are numerous factors to be considered in the selection of a sling for

a particular task or range of tasks. These will include the sling type, the
material it is made from, and its configuration. For example, the number of
sling legs and what terminal fittings are required. Or the type of hooks.

Environmental operating conditions should also be considered.

137
Module G | G.3. Wire Rope Slings

Wire Rope Slings

Wire rope slings are very popular for general lifting duties.

Slings of all configurations can be assembled from wire rope and will be found in service. In general
industry, the most common type of wire rope sling in service is the single leg as shown below.

In addition, 2, 3 and 4-leg wire rope slings are also available. A 2-leg sling is shown below:

Hand Spliced Eyes

The hand spliced eye is an eye formed at the end of a sling by the traditional method of threading the
individual strands of the rope back along the main body of the rope in a prescribed pattern.

This type of eye is now less popular than the more modern ferrule-secured eye, but it is still available and
preferred by some users.

Flemish Eye

A tapered steel ferrule is passed over the rope. The standing part of the rope is then taken, and three
strands are unravelled and opened so that a ‘Y’ formation is made.

The ends of the strands are then evenly distributed around the intact standing part of the rope to complete
the eye. The ferrule is then slid back over the distributed wires without displacing the strands and then
pressed. The ferrule compresses and grips the rope.

The illustration below shows how a Flemish Eye is made:

138
Module G | G.3. Wire Rope Slings

Turn Back Loop

This is a cheaper yet highly effective option and therefore is perhaps used more commonly for general
purpose slings.

With this method, an aluminium ferrule is used to secure the eye made at the end of the rope.

Thimbles

Thimbles are essential components in the construction of wire rope slings.

They serve as protective inserts fitted to the eyes of sling legs during manufacture. Their primary function
is to safeguard the sling eye from abrasion, deformation, and point loading to extend the working life of the
sling and maintain safety during lifting operations.

The illustration below shows how a thimble is incorporated into the eye of a wire rope sling during the
manufacturing process:

139
Module G | G.4. Textile Slings

Textile Slings
There are several types of fibre slings, each of which is designed for specific applications and load types.

Synthetic Webbing Slings Synthetic Round Slings Fibre Rope Slings

Synthetic Webbing and Round Slings

Webbing slings and Round Slings can both be manufactured from the following materials:

• Polyester
• Polyamide (Nylon)
• Polypropylene
• Aramid Polyamide

Webbing Slings

Sometimes referred to as ‘belt slings’, these flat, woven

webbing slings are used for general-purpose lifting operations.

The webbing is the material of a web sling, made from tightly

woven synthetic fibres. This material is usually flat and comes
in various widths, thicknesses, and strengths.

• They are soft and easy to handle but rigid across their
width.

• They are ideal for handling loads which require some

support when being lifted as the load is spread across the
full width of the webbing, avoiding point contact which
can be an issue with chain or wire rope slings. They are
therefore less likely to cause damage to the load’s surface.

One disadvantage is that they are less robust and therefore

can easily be damaged in service.

140
Module G | G.4. Textile Slings Required Activity
!
Round Slings

Round slings have a core which is enclosed in a protective cover.

The core is the load-bearing part of the round sling. The core is a
long, continuous yarn of interlocked fibres which are then joined
together to make an endless loop (the core).

The protective cover is a woven tubular outer sleeve of the same

parent material as the core, which is designed to be non-load-
bearing as it is intended only for protection and to contain the
core.

• Synthetic round slings are an endless textile sling that is soft

and pliable to use, easy to handle and especially useful on
delicate surfaces.

• They are less robust and more liable to damage than

equivalent capacity wire rope and chain slings.

The illustration below shows a round sling being manufactured. The core can be seen with the black tape
in place which simply secures the ends of the yarn. The protective cover is in place and ready to be pulled
over the whole of the yarn before it is stitched together at its ends.

Fibre Rope Slings

A traditional form of sling made from splicing eyes into the ends of the rope. These are less likely to be
found in service nowadays.

Turbo Engineering purchasing department have been asked to purchase 12 x 1 metre EWL (effective
working length) Duplex webbing slings, 1000Kg WLL for use in the forklift maintenance and battery
charging bay.

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

What information would the purchasing team need to specify the correct type of
webbing sling to their supplier?

141
Module G| G.5. High Modulus Polyethylene (HMPE)

High Modulus Polyethyline (HMPE)

High Modulus Polyethyline (HMPE)
HMPE is very strong, lightweight, and durable, making it perfect for lifting heavy loads in
many industries. HMPE rope is a high-performance rope made from Ultra-High Molecular
Weight Polyethylene Fibres (otherwise known as UHMWPE).

It can handle tough conditions without losing its strength, ensuring safe and efficient lifting
and is used in several applications, for example:

• Heavy-lifting and Rigging Applications: HMPE ropes and slings are used in various lifting and rigging
applications, from industrial cranes to offshore oil rigs. Their high strength and low weight make them
ideal for heavy-lifting tasks.

• Winching Applications: HMPE lines provide strong and reliable performance with minimal stretch,
ensuring precise control during winching operations.

• Safety Systems: In safety applications, such as fall protection systems, HMPE fibres are used to
manufacture strong, lightweight, and reliable safety lines and harnesses.

• Marine and Offshore Applications: HMPE is extensively used in marine and offshore industries for
mooring lines, tow ropes, and lifting slings due to its resistance to water, salt, and harsh weather
conditions.

142
Module G | G.6. Shackles

Shackles
Shackles
Shackles are likely the most widely used and versatile lifting accessory. They have a wide
range of applications, including:

• Connecting a load directly to a lifting device

• Attaching slings to the load and/or lifting appliance
• Serving as the suspension for lifting equipment
• Acting as the head fitting in some pulley blocks

Today, there are two common types of shackles used for lifting:

Dee Shackles

Shackle standards specify dee shackles, with some specifying

both a large dee and a small dee shackle.

• Large Dee Shackle: A large dee shackle is a shackle which

has larger internal clearances in the body and jaw, and which
is appropriate for general engineering purposes.

• Small Dee Shackle: A small dee shackle is a shackle which

has smaller internal clearances in the body and jaw but, size
for size, has a SWL higher than that of the large dee. It is
suitable for use with hook eyes, eyebolts, egg links, wire rope
thimbles, etc. and the head fittings of ships’ blocks.

Key Point:
Dee shackles are not suited for angular or side loading compared to bow shackles, as their
design focuses on linear (straight line) loading.

Bow Shackles

Shackle standards also specify bow shackles, with some specifying

both a large bow and a small bow shackle.

• Large Bow Shackle: A large bow shackle is a shackle which

has larger internal clearances in the body and jaw, and which is
appropriate for general engineering purposes.

• Small Bow Shackle: A small bow shackle is a shackle which has

smaller internal clearances in the body and jaw but, size for size,
has a SWL higher than that of the large bow. It is suitable for use
with the eyes and bodies of hooks, eyebolts, egg links, wire rope
thimbles, etc. and for the head fittings of ships’ blocks.

143
Module G | G.6. Shackles

Bow shackles have a wider, more rounded design, allowing for greater movement and flexibility. They are
suitable for multi-directional loading.

Key Point:
Shackles are normally forged from various grades of steel. Higher-quality alloy steels give a
higher safe working load than those made in higher tensile steels.

Shackle Load Pins

There are multiple types of shackle load pins, but the most commonly used are:

Screw Pin

Bolt, Nut, Split Cotter Pin

The choice of pin depends on the circumstances of use:

• For general use, and where there is no tendency for the pin to unscrew and the shackle can be
observed in use, screw pins with eye and collar are very satisfactory and easily used.

• For permanent installations or where there is an inherent tendency for the pin to unscrew or when the
shackle cannot be observed, pins comprising bolt, nut and split cotter pin are recommended.

144
Module G | G.6. Shackles Required Activity
!

Mike Menditt has fitted a push travel trolley to the beam

of a jib crane. He will be suspending a hand chain hoist
from the trolley suspension eye and will use a 3t WLL
shackle for this purpose.

Mike visits the stores to get a shackle and meets up with Steve Stockton, the Storeman. Steve offers Mike
either of the shackles shown in the image above.

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

Which of the shackles should Mike select for his application, and why?

145
Module G | G.7. Eyebolts

Eyebolts
Eyebolts
Eyebolts are one of the most widely used items of lifting accessories, but they do have strict
limitations in use. Multiple accidents have occurred as a result of misuse.

There are three main types of eyebolts commonly found in service.

Dynamo Eyebolt Collared Eyebolt Collared Eyebold with Link

The is the most basic in design Designed for both axial and an- This eyebolt is ideal for angled
and the most limited in use be- gular loads, the eye is integrated loading, allowing loads up to 15°
cause it is only suitable for axial with the collar in one plane. A from the screw thread axis in any
(directly vertical) lifting. shackle is required for connec- direction while maintaining its full
tion to hooks, as the eye is too SWL rating.
small for direct attachment.

Key Point:
When using collared eyebolts in pairs with a 2-leg chain sling, they must be aligned within +/- 5
degrees of each other.

146
Module G | G.8. Hoist Rings

Hoist Rings
Hoist Rings
Hoist rings are lifting accessories used to lift objects safely. They are usually attached to
machinery or equipment and are designed to handle the stresses of lifting.

Unlike standard eye bolts which offer a stationary lifting point, hoist rings can rotate and
pivot, which helps keep the load under control and reduces the risk of damage during lifting.
This makes them ideal for moving large or heavy items with precision.

Hoist rings typically require a specified torque setting to ensure they function safely and effectively. The
hoist ring below clearly states that it must be attached to the load with a torque setting of 38Nm.

147
Module G | G.9. Load Lashing Equipment

Load Lashing Equipment

Thousands of loads are transported on roads every day. Without proper securing, these loads can become
dangerous. If loads are not properly secured, they can move around, fall off, or cause accidents, posing
risks to other vehicles and people on the road.

It’s important to understand the forces that can affect loads during transit, know the different methods for
securing loads, and use the right equipment to keep everything in place. Proper training on how to secure
loads correctly is crucial to ensure everyone’s safety and protect the cargo and vehicle from damage.

The Problem
• Loads on-road vehicles are subjected to the forces generated due to the vehicle accelerating, braking
and cornering.

• The magnitude of these forces will vary according to the type of vehicle, the road surface and the
quality of driving as well as the nature, weight and shape of the load.

• The effect of the forces on an unrestrained load will be for the load to slide or topple. Therefore all loads
need to be adequately secured in transit, and the underlying principles are the same for them all.

The Solution

148
Module G | G.9. Load Lashing Equipment

There are two methods of securing loads to vehicle trailers by lashing the load:

• Friction lashing: otherwise known as Over-the-Top Lashing.

• Direct lashing: The load is directly connected to the vehicle or its trailer.

In the illustration on the left we see the friction lashing method. The wooden crate is secured by the lashing
friction from the webbing straps under tension.

The direct lashing method is illustrated below where the dumper truck is directly secured to the frame of
the lorry bed by 4 lashings.

Direct lashing can only be used when both the load and the bed are equipped with lashing points
compatible with the required strength of the lashing.

The Equipment
Load lashing is generally facilitated by using either webbing or chains.

149
Module G | G.10. Reflective Learning Required Activity
!

Mike Menditt has selected a 2-leg chain sling and 2 x eyebolts to lift a steel counterweight onto a
forklift that has just been repaired. The illustration below shows the arrangement and exact lifting
accessories Mike intends to use. The eyebolts will be screwed into two tapped holes in the top of the
counterweight and the chain sling will be attached to the eyebolts ready for the lift.

Lifting Accessories

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

Assuming Mike has selected the lifting accessories which have the correct SWL for
the lift, and that the angle of the sling legs has been calculated at 35 degrees from
the vertical, is there anything that Mike needs to consider before carrying out the
lift, or would you approach this lifting operation differently?
Refer to COPSULE s.20.3.3.

150
Module G | G.11. Knowledge Check Required Activity
!

If accessing this Course Handbook from a mobile or electronic device, click on the correct
answer and then select “Submit” to send in your response.

If using this Course Handbook in its printed version, simply tick the correct response using a pen.
Then refer back to your answers when it’s time for you to input your responses in the LEEA App.

Chain slings may be the preferred lifting accessory used for lifting which of the
following types of loads?

Light weight loads

Sharp-edged loads

Soft material loads

The material of a webbing sling is constructed from which of the following?

Woven synthetic fibres

Strands of fine aluminium

Natural fibres spun together

Wire rope slings are popular for what type of lifting?

Lifting lightweight loads only

Lifting delicate loads

General lifting

Winching operations require a particular textile material that has minimal stretch characteristics.
What textile would be most suitable for winching applications?

Polyester

High Modulus Polyethylene

Polypropylene

151
Module G | G.11. Knowledge Check Required Activity
!
What is the main operational advantage between a hoist ring and an eyebolt?

Hoist rings do not need to be tightened onto the load

Eyebolts have higher Working Load Limits

Hoist rings can swivel and pivot

In the context of Load Lashing Equipment, what is ‘direct lashing’?

The load is directly connected to the vehicle or its trailer

The shortest possible lashings are used top reduce costs

The load is held securely by friction from the lashings

152
MODULE H

Lifting
Appliances

153
153
Module H | H.1. Learning Outcomes

WELCOME TO MODULE H

Lifting Appliances
At the end of this module, we expect that the students will be able to:

• Identify different types of lifting appliances and understand their functionality, application and
limitations of use.

ASSESSMENT CRITERIA
At the end of this module you will be able to:

• Identify the different types of lifting appliances.

• Understand the basic methods for lifting appliances and their potential misuse.

Note:
We estimate that it will take approximately 2 hours to complete this module.

154
Module H | H.2. Bridge and Gantry Cranes

Bridge and Gantry Cranes

Bridge and gantry cranes provide a means of lifting and transporting loads over the area covered by the
crane. Some bridge and gantry cranes may use manual effort to lift, lower and move the load. However, it is
more usual for some, or more typically all, of the crane’s motions to be electrically powered. There are four
main types:

• Top-running bridge crane

• Under-slung bridge crane
• Semi-portal gantry crane
• Portal gantry crane

Top Running Bridge Crane

This bridge crane runs on top of rails that are part of the crane-supporting structure.

Underslung Bridge Crane

This bridge crane runs on the bottom edges of the crane tracks. Because of the under-slung arrangement,
the bridge of this type of crane can have a cantilever at one or both ends.

Two or more such cranes running on parallel sets of tracks can be fitted with latching mechanisms to
facilitate the transfer of loads from one crane to another.

155
Module H | H.2. Bridge and Gantry Cranes

Semi-Portal Gantry Crane

Sometimes referred to as a ‘semi-goliath’
crane, the semi-portal bridge crane is a
type of crane used in various industrial and
construction applications. It combines the
features of both portal cranes and bridge
cranes offering versatile functionality.

One end of the crane is a bridge style

which runs on the building’s crane-
supporting structure whilst the opposite
end of the crane is an ‘A’ frame which is
fixed to a carriage running on tracks in the
floor.

Semi-portal bridge cranes are ideal for

situations where a full portal crane may
be too much of an obstruction to the work
area or where space limitations call for
a flexible design. They are internally and
externally lifting loads over large areas.

Portal Crane
Sometimes referred to as a ‘gantry crane’ or ‘goliath crane’, portal cranes are a type of crane supported by a
structure similar to a bridge or gantry. These cranes are used for various industrial applications, including:

• Shipyards
• Rail yards
• Construction sites
• Ports

Portal cranes often have wheels mounted on rails, allowing them to travel the length of the workplace. This
mobility is beneficial for loading and unloading operations across large areas.

156
Module H | H.3. Supporting Structures

Supporting Structures
Supporting Structures
Supporting structures are used to mount lifting appliances. They are more commonly known as ‘fixed’
or ‘mobile’ structures, and in this course we will explore both types.

Fixed Supporting Structures

These are primarily used to support a lifting appliance which enables loads to be lifted, travelled and
lowered along their length or within the footprint of their floor area coverage. They include:

• Runways
• Slewing jib cranes
• Crane gantries

Mobile Supporting Structures

These are widely used in industry in conjunction with hand or power-operated lifting appliances where a
temporary runway structure is required to perform both lifting and linear moving operations. They include:

• ‘A’ frame mobile supporting structure

• Adjustable height mobile supporting structure
• Goalpost Mobile Supporting Structure
• Foldaway mobile supporting structure
• Self-erecting mobile supporting structure
• The demountable mobile supporting structure

Runways
Runways can be manufactured from standard rolled steel sections or special track sections.

They can be supported by building structures, dedicated free-standing structures or a combination of both.

Runways offer a cost-effective alternative to overhead travelling cranes. Their design can range from a
simple beam section to a more complex system which may include directional switching, turntable and
curved sections allowing the load to be redirected along the structure at given points.

157
Module H | H.3. Supporting Structures

Special Track System Turntable Special Track System Switch

These can redirect the load to other sections of the track as This enables the redirection of the
required. The hoist trolley mechanism enters the turntable hoist trolley to a different track,
and the operator rotates the turntable to the track section something like train tracks which
required. When the rotation is complete, the tracks align are switched to divert trains onto
and the hoist trolley can be moved onto the new section of different lines.
the track.

Built-in Supporting Structures

Built-in supporting structures are usually runway beams supported by the existing building structure. The
‘cantilever’ and ‘encastré’ type runways are the most common.

Suspended Runways
Suspended runways are suspended from suitable roof structures or additional beams built into the building
structure.

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Module H | H.3. Supporting Structures

Free-Standing Runways
These are used when there are no suitable existing supports available. The illustration below shows a free-
standing supporting structure for a top-running bridge crane in the background and a runway beam in the
foreground.

Slewing Jib Cranes

Slewing jib cranes are widely used alongside

manual or powered lifting machines where a
permanent facility is required to perform lifting
but within limited moving operations.

They offer a wide area of floor coverage within

the slewing radius (this can be a limited radius
or a full 360° rotation) of the arm and they
are ideal where full overhead travelling crane
coverage is not necessarily required.

159
Module H | H.3. Supporting Structures

Wall-Mounted Jib Cranes

Wall-mounted jib cranes are mounted to a vertical structural support and offer up to 180° of rotation.

They offer a wide area of floor coverage within the slewing radius (this can be a limited radius or a full 360°
rotation) of the arm and they are ideal where full overhead travelling crane coverage is not necessarily
required.

Crane Gantries (Tracks)

These are generally manufactured from standard constructional sections.

• Top-running cranes: a rail section is usually welded to the top flange of the track beam.

• Under-slung cranes: the crane will run on the bottom flanges of the beam. Depending on the crane
type the track will either be suspended from a cross beam known as a carrier beam or fitted directly to
the tops of the supporting columns.

Rails
Depending on the duty, the rail will have a profile similar to one of those shown below, but more often than
not for light duties, this will be a square bar. These rails are normally fixed by intermittent welding and if not
welded with the rail securely clamped to the beam weld, cracking will occur in service.

160
Module H | H.4. Supporting Structures (continued)

Supporting Structures (continued)

Mobile Supporting Structures
A mobile supporting structure is a large, movable frame that helps lift and move heavy objects. It’s a
large frame with a lifting device, like a hand chain hoist, attached to a trolley that moves along the frame.

These structures are typically mounted on wheels or castors, allowing them to be easily moved by hand.
Some may have fixed feet, meaning they need to be taken apart for transportation.

They are designed to be portable and adjustable, made from strong materials like steel or aluminium,
and can lift up to 5 tons. Mobile supporting structures are flexible and commonly used in places where a
permanent lifting system would be too expensive, such as workshops, fabrication areas, and garages.

161
Module H | H.4. Supporting Structures (continued)

Adjustable Height Supporting Structures

This type of support structure offers a limited range of height settings to suit different user requirements.

The height adjustment is carried out in a non-loaded situation.

Goalpost Mobile Supporting Structure

The simplest form of mobile supporting structure is the goalpost type.

This comprises a runway beam, often of the proprietary track section, with single-column supports. Lateral
stability is provided by a base member on which the column is mounted. This design is limited to light loads,
usually up to 500kg, and light-duty applications.

Foldaway Mobile Supporting Structure

Foldaway mobile supporting structures are designed for easy dismantling and storage.

They are intended for applications where regular dismantling and transportation are necessary or where the
usage is such that long periods of storage occur. This design is usually limited to loads of up to 2 tonnes.

162
Module H | H.4. Supporting Structures (continued)

Demountable Mobile Supporting Structure

Demountable mobile supporting structures are a further design variation which permits the structure to be
dismantled for relocation.

The construction is fully bolted, although some joints may utilise locking pins, which enables the structure
to be dismantled and erected using other lifting facilities to assist in the operation.

Demountable mobile supporting structures are intended for applications where long periods of service with
occasional dismantling for storage or transportation are necessary. This design is available in all capacities,
usually up to 5 tonnes.

Self-erecting Mobile Supporting Structure

Self-erecting mobile supporting structures are designed with the provision of hand-winching mechanisms
which allow the structure to be assembled horizontally on the floor.

Operation of the winches pulls the side members of the ‘A’ frame supports together until the mobile
supporting structure is in its operating position.

Additional locking structural components are then inserted making the structure rigid. This design is usually
available in higher capacities from 2 tonnes upward.

163
Module H | H.5. Manual Lifting Machines

Manual Lifting Machines

Manual Lifting Machines
Manual lifting machines are tools that help lift, move and manipulate heavy objects without
the need for electric, internal combustion or hydraulic power.

They use simple mechanisms like levers, pulleys, and gears to make lifting easier and safer.
These machines are commonly used in environments where powered lifting equipment is not
suitable or practical.

Hand Chain Hoist

Hand chain hoists are very popular and are found in wide use throughout the world. This is because they
can be used very effectively in the following applications where:

• A permanent installation for infrequent use is required

• A temporary installation for erection or maintenance purposes is required
• The precise location of the load is required
• A suitable power supply is not available

Chain hoists use a pocketed wheel into which the load chain must fit, but freely enter and leave. The drive
to the pocketed wheel is via a hand chain and screw brake mechanism and the free end of the load chain
is fitted with a chain end stop which prevents it from passing through the hoist completely. The illustration
below shows this arrangement:

164
Module H | H.5. Manual Lifting Machines

Modern Hand-Operated Hoist

All modern hand-operated hoists are fitted with an automatic brake which, when functioning correctly, is
capable of arresting and sustaining the load at any position.

Manual Chain Hoists are suspended from their supporting structure from a top hook, shackle or lifting eye
built into the hoist body, or they may be built into a travelling trolley arrangement:

Manual Chain Hoists

Some manual chain hoists are designed for use at an angle from
the vertical but the instructions from most manufacturers state
that they are intended for vertical use only.

When use at an angle is contrary to the manufacturer’s

instructions, the user must carry out a risk assessment and
provide adequate instructions for the application. The hoist’s
performance and safety could be compromised if adequate
consideration and precautions are not taken for angular loading.

This can be done safely within certain parameters provided

appropriate precautions are taken.

Key Point:
The hook must never be passed around a load and back-
hooked onto the chain as shown on the right.

165
Module H | H.5. Manual Lifting Machines Required Activity
!

Steve Stockton, Turbo Engineering’s Storeman has just received a hand chain hoist from Osprey Lifting.
The hoist has been ordered for Mike Menditt for fitting to a trolley on a swing jib crane.

As Steve checks the hoist into the stores, he finds a Declaration of Conformity and User Instruction
Manual inside the box for the hoist.

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

What should Mike do with the Declaration of Conformity?

Put the declaration in the official records to prove traceability and

conformity for the hoist

Note the contents of the declaration in a computer spreadsheet and then dispose of
the paper declaration

Put the declaration in a plastic pouch and connect it to the hoist

166
Module H | H.6. Manual Lifting Machines (continued)

Manual Lifting Machines (continued)

Lever Hoist

Hand-operated lever hoists are widely used in many areas of industry because they can perform both
lifting and pulling applications. The ability of the lever hoist to operate at any angle makes the lever hoist
a versatile tool, particularly for rigging. It can be used as an adjustable sling leg to enable a load to be
balanced or for line adjustment when positioning - to give just two examples.

Two basic types of lever hoists are available, each with a different load chain:

• Fine tolerance (calibrated) short-link steel chain

• Roller chain

Key Point:
The fine-tolerance short link chain is shown on the left of the image below, and the roller chain is
on the right.

Advances in material and manufacturing technologies have enabled much smaller, lighter, and more efficient
lever hoists to be produced.

167
Module H | H.6. Manual Lifting Machines (continued)

Lever hoists (similar to the manual chain hoist) use a pocketed wheel into which the load chain must fit
but freely enter and leave. The drive to the pocketed wheel is via a ratcheting lever and screw brake
mechanism.

The lever hoist will also have a change-over lever with a neutral position allowing the user to set the chain
to the correct length (free-wheel facility). The free end of the load chain is fitted with a chain end stop to
prevent it from passing through completely.

Lifting and Pulling Machines

Commonly referred to as ‘jaw’ or ‘creeper’ winches in different regions, these machines are widely used
throughout the industry for both permanent applications and temporary or rigging applications.

They are used as pulling machines as well as lifting, which may permit a lower factor of safety and give
a higher working load limit when the winch is used for pulling. These machines are normally manually
operated but are available as hydraulically operated units. Hydraulic machines are connected to a hydraulic
pump unit specifically for the machine being used.

The wire rope supplied for use with a jaw winch should be considered as integral a part of the mechanism
as a load chain of a chain hoist.

168
Module H | H.6. Manual Lifting Machines (continued)

Some ropes, which appear to be of the correct size, and which are accepted by the winch, may not be
suitable. The efficiency and safety of the friction grip of the winch jaws depend entirely on the rope being
the right diameter and constructed to withstand the crushing force of the jaws.

With a rope diameter that is too small, the jaws will not grip the rope sufficiently. With a rope diameter that
is too large, the rope may become stuck in the machine, putting it out of operation.

It is therefore essential that only ropes approved by the manufacturer are used with the specified machine.

One end of the load rope is plain tapered and fused to allow entry into the machine. The other end has a
terminal fitting for attachment to the load.

Jacks

Jacks are widely used for lifting purposes where loads need to be raised or lowered within a limited
distance.

Jacks are mechanically or hydraulically powered and there are several types available. The range of jacks
includes pneumatic and electrically operated units and those designed for road vehicles.

Hydraulic Jacks
Hydraulic jack bodies are commonly manufactured from aluminium, steel or cast iron.

The material used affects the design, size, self-weight and capacity of the jack. Hydraulic jacks use oil and
the body of the jack acts as a reservoir for the oil. When the jack is operated, the oil is passed through a
system of non-return valves to the underneath of the lifting ram.

When more oil is delivered through each stroke of the handle, the lifting ram is forced out of the chamber
lifting the load. The load is lowered by opening a valve which allows the oil to return to the reservoir by the
load pushing down onto the lifting ram.

A typical hydraulic system is illustrated below. We will explore this in greater detail in the Manual Lifting
Machines Diploma.

Screw Jacks
Consists of a single hollow casting with a square form female thread into which fits a male screwed shank.
A swivel head is fitted to the shank to support the load.

Directly turning the screwed shank causes it to raise or lower.

169
Module H | H.6. Manual Lifting Machines (continued)

Journal Jacks
Consist of a cast body which houses a bevel gear and screw mechanism. Operation of a ratchet lever turns
the gears which drive a screwed shank. This in turn drives a running nut which is captive in the lifting journal
and therefore causes the journal to raise or lower.

Ratchet Jacks
The body of the ratchet jack contains a pair of pawls that engage in a rack.

Operation of the jack causes the pawls to raise or lower the rack, which is fitted with a lifting head and toe,
providing alternative positions for supporting the load.

The full-rated load may be supported on the head or at a reduced loading on the toe.

During the jacking operation, the operative effectively carries the load via the operating lever. At the end of
each stroke, the load is sustained by a pawl.

170
Module H | H.7. Powered Lifting Machines

Powered Lifting Machines

Powered Lifting Machines
Powered Lifting Machines are mechanical devices designed to lift, move, and position heavy
loads with minimal human effort.

They are commonly used in various industries, including construction, manufacturing,

warehousing, and logistics, to enhance productivity and ensure safety when handling heavy
materials.

Powered lifting machines are available with electric or pneumatic operation, but the most common in
general use at present are electrically operated. These are ideal for heavier or repetitive lifting applications
as they offer the following advantages over manually operated chain hoists:

• Speed of operation
• Less fatigue for operatives, particularly on long lifts
• Operatives may be remote/away from the load

Electric Chain and Wire Rope Hoists

Modern electric power-operated hoists are normally fitted with low voltage control which is derived
internally within the unit by a transformer. This is usually in the range of 24 to 50 volts AC or DC and is often
known as ‘Extra Low Voltage’ and is designed for electrical safety.

Older hoists and special-purpose hoists may not have low voltage control. It should also be noted that it is
common in many European countries to use mains voltage control. The three principal lifting media used
with all power-operated hoists are:

• Short link round steel chain

• Steel wire rope
• HMPE and textile belt materials

Hoists Using Chains

The chain passes over a pocketed wheel, in the same way as we have seen in manual chain hoists and
lever hoists, with the slack side of the chain hanging loose. A collecting box may be used to house the slack
chain, but as this sits below the body of the hoist it restricts the height that certain loads may be lifted.

171
Module H | H.7. Powered Lifting Machines

Hoists Using Wire Rope

The wire rope passes on and off a drum upon which it is stored. The lift range is limited by the amount of
wire rope that the drum can accommodate.

Pneumatic Hoists

Pneumatic power-operated hoists tend to be more limited in terms of use in comparison to electric power-
operated hoists. This is mainly due to the problems associated with suitable air supply provision.

However, they offer many advantages over electrically operated equipment and as a result are widely used
in industries where the air is provided for other purposes or where the safety aspects associated with air-
operated equipment are a major consideration.

Hydraulic Hoists

The hydraulic hoist enables smooth, precise lifting and lowering, operating quietly. It uses an electric motor
to power a hydraulic motor. The hydraulic motor is a mechanical device that converts hydraulic pressure
and fluid flow into rotational force (torque), which drives the hoist’s movement.

One key advantage of this system is that the electric motor can be placed away from the hydraulic drive,
significantly reducing noise levels.

Hydraulic hoists are often used in areas where safety is critical, similar to pneumatic hoists, as they can be
designed for use in hazardous or explosive environments.

Electrical Controls

Other control options, such as radio or infrared controls, enable remote or central control. They are useful
in areas where direct access may not be possible. Multi-point controls, usually wall-mounted, enable
hoists to be controlled from several positions, which is useful in applications such as raising loads through
several floor levels. Such arrangements must be suitably interlocked to prevent more than one control from
operating at a time.

A further essential requirement with this arrangement is the provision of emergency stop buttons to
override all control positions until manually reset.

172
Module H | H.7. Powered Lifting Machines

Hydraulic hoists are often used in areas where safety is critical, similar to pneumatic hoists, as they can be
designed for use in hazardous or explosive environments.

173
Module H| H.8. Reflective Learning Required Activity
!

Turbo Engineering technicians are having difficulty completing a fabrication job as they cannot seem to
position the machinery into the correct position for welding into place.

Mike Menditt has been asked to look at the job as the appointed person for lifting operations and
advise the technicians on how best to place the load into the correct position.

When Mike arrives he looks into the agricultural machinery being manufactured and takes a
photograph of the image shown below.

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

174
Module H| H.8. Reflective Learning Required Activity
!
What action would you take, and what advice would you give in this situation if you
were in Mike’s position, and why?

Refer to LEEA COPSULE section 1A6.3 - principles for the selection of lifting appliances. Many
considerations should be made before selecting lifting appliances.

There are numerous factors to be taken into account when selecting a

lifting appliance for a particular task or range of tasks. These will include
assessing the operation, deciding on the type of appliance, together with
any control options, and what it will be suspended from.

In the case of power operated lifting appliances, the type of power, for
example, hydraulic or electric, and if appropriate, the power feed system
will also have to be considered.

Finally, some additional safety devices may be required to ensure that the
system as a whole is safe.

Turbo Engineering has recently initiated a project which will involve the assembly, testing and
packaging of a new agricultural crop testing machine. The machine will be assembled from small
components on a workbench and then placed directly into its shipping container for despatch to the
customer.

They have identified an area in their factory where the work will be carried out. Karen Keeper is
currently inviting suppliers to offer their quotations to supply the machine components, tools, racking
and workbenches for the assembly area, together with additional electrical and lighting supplies that
will be needed.

175
Module H| H.8. Reflective Learning Required Activity
!
The HR department has interviewed and selected two new employees for the assembly build area and
they will be commencing employment within the next 2 weeks. Karen has received all the quotations
and she is now briefing senior managers on the project’s progress.

I am pleased to inform you that we’ve received all quotations for the
equipment we need for the assembly area and orders will be placed over
the next two weeks. The machine build process has been established and
we have the outsourced components being delivered to us over the next
few days.

Order have already been received for the crop testing machine and we
hope to deliver the first of these in 6 weeks. We will be using a national
courier for delivery of the machine which should weight approximately
125 Kg.

Does anyone have any questions at this time?

Yes, I have a question.

Has anyone been consulted about how the assembly team will lift the
completed test machine from the assembly bench, package it, and move
it to the despatch area for shipment?

Oh! I don’t believe anyone has asked me about that.

I guess the assembly team will just have to use whatever is available
on the day to the the job, after all, it’s not a big deal. The machine only
weighs 125 Kg.

Reflect about what you have learned throughout this section, then
type your answer in the boxes provided. These will be monitored
by a member of LEEA Academy Training Team.

176
Module H| H.8. Reflective Learning Required Activity
!
Is Karen demonstrating all of LEEA’s behaviours for a safer world of work here? If not,
which of the following important behaviours appear to be missing from her attitude?

Lead by example

Engage in effective communication

Look after yourself and others

Carry out your work with due care and diligence

Who should have been consulted earlier in the project to discuss the equipment that may
be required for lifting, lowering and transportation of components to the assembly area,
and the transfer of the assembled machine to the despatch area?

The company’s appointed person for lifting operations - Mike Menditt

The new employees at their interview

The health and safety representative

Who is responsible for ensuring that workers who will use any new lifting equipment are
competent to do so?

Outsourced training contractor

Karen Keeper - Purchasing Manager

Mike Menditt - Appointed Person

During the lift planning, Mike will need to consider that the newly assembled machines may be
prone to damage and require some support when they are lifted as a unit from the assembly
bench. There are slinging points built into the machine frame. What type of lifting sling would be
the best for this application?

Textile sling

Chain sling

Wire rope sling

177
Module H| H.8. Reflective Learning Required Activity
!
Workers using any lifting equipment to perform a lifting operation should be competent to
do so. Which of the following are not required elements of competency? (You may choose
multiple answers from the following list)

Suitably qualified

Hold an engineering degree of equivalent

Suitably trained

Hold at least two LEEA Diplomas

Suitably experienced

Be of a minimum of 21 years of age to use high-risk machinery

Which of the following would you consider as a suitable solution for the new assembly area
to lift the assembled machines onto a pallet for transfer to the despatch area? (You may
select multiple answers)

A slewing jib crane

Lever hoist

Bridge crane

A runway and hoist / trolley

Chain slings

Portal crane

Tower crane

178
Module H | H.9. Knowledge Check Required Activity
!

If accessing this Course Handbook from a mobile or electronic device, click on the correct answer
and then select “Submit” to send in your response.

If using this Course Handbook in its printed version, simply tick the correct response using a pen.
Then refer back to your answers when it’s time for you to input your responses in the LEEA App.

What type of cranes can be fitted with latching mechanisms to facilitate the transfer of loads
from one crane to another?

Portal cranes

Top-running bridge cranes

Under-slung bridge cranes

What type of crane is shown in the illustration above?

Under-slung bridge crane

Semi-portal crane

Top-running bridge crane

Adjustable height supporting structures may only be adjusted in which of the following
circumstances?

At any time as long as the load being lifted is less than 50% of the WLL

At any time, loaded or unloaded with no restriction

In unloaded conditions only

179
Module H | H.9. Knowledge Check Required Activity
!
How are modern, electrically powered lifting machines designed for electrical safety?

By reducing control voltage between 24 & 50 volts AC or DC

They have rubber control stations

Battery powered remote control stations are always used

When using a hand chain hoist at an angle other than vertical, against the operating
instructions provided by the manufacturer, what are the possible consequences if the lift has
not been risk assessed by a competent person and no instructions for the lift are provided?

A risk assessment is not necessary so there will be no consequences

The performance and safety could be compromised

The load could be damaged due to additional forces

Which of the following is a runway beam supporting structure that is built into the building
structure at each end?

Cantilever

Free standing

Encastre

180
MODULE I

Purchasing
and Control
of Lifting
Equipment

181
181
181
Module I | I.1. Learning Outcomes

WELCOME TO MODULE I

Purchasing and Control of Lifting Equipment

At the end of this module, we expect that the students will be able to:

• Understand the selection, purchasing and in-service control processes for lifting equipment.

ASSESSMENT CRITERIA
At the end of this module you will be able to:

• Explain the specific requirements of equipment selection that must be fully considered by
those purchasing lifting equipment.
• Explain the importance of correct storage of lifting equipment.
• Explain the marking requirements for various types of lifting equipment and how missing or
illegible markings can become risks to safety in use.
• Explain responsibility for safe and responsible disposal of lifting equipment following its life
span.
• Identify the various inspections, examinations and maintenance that must be performed on
lifting equipment.

Note:
We estimate that it will take approximately 2 hours to complete this module.

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Module I | I.2. Purchaser’s Responsibilities

Purchaser’s Responsibilities
Purchaser’s Responsibilities
Procurement personnel are responsible for selecting equipment that is most suitable for its
intended use. To do this, they need to ensure the specification covers:

• A thorough understanding of the equipment

• The environmental conditions in which it will be used
• The required operational capacity
• Relevant legislation and standards

Procurement personnel must be able to create tenders that clearly define the minimum performance
requirements and reference the appropriate product safety standards. Equipment should be chosen based
on its ability to perform safely in all foreseeable conditions, as identified in a risk assessment, rather than
based solely on cost.

Procurement personnel needs to understand technical specifications and assess whether the equipment
meets the risk-assessed criteria.

Those responsible for bringing equipment into use must ensure it complies with all essential health and
safety requirements. This is typically achieved by confirming that the necessary documentation is provided
with the equipment and that it is properly marked following the relevant standards and regulations.

Training Requirements
All lifting operations should start with a ‘lift plan’. This is the responsibility of an appointed person
(competent person) who will specify the lifting equipment that is required for specific operation(s).

If there are no trained personnel to use the equipment requested, it should not be purchased until suitably
trained personnel are available.

The appointed person is therefore responsible for ensuring the company has the necessary competencies
available to use the equipment that is being specified for purchase.

The purchaser of the lifting equipment should therefore follow the exact specification of the lifting
equipment that is being requested by the appointed person so that it can be used competently and safely
when it arrives on site, aligned to the lift plans that have been created.

Documentation Requirements

Key Point:
This section is a reminder of the documentation requirements covered in the Conformity section
(E4).

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Module I | I.2. Purchaser’s Responsibilities

Who?
• It should be clear in the documentation who the manufacturer and/or importer/distributors are,
as applicable regulations may define different obligations and responsibilities to these economic
operators.
• In some cases, the involvement of a third party may be required to assess whether the product
conforms to legislation.

What?
• It should be clear in the technical documentation what the equipment type is, its intended use and its
performance (e.g. working load limit).

• To make the declaration of this information easier, most products on the market will have a standard or
technical specification clearly defining these requirements. In this case, the manufacturer can simply
declare compliance with the standard. This reference should be unambiguous and unconditional.

• Some information can be legal and, in that case, it should be clear what legal framework applies. As an
example, simply claiming that a product is CE-marked (in Europe) is not enough. A construction product
may be CE marked under the Construction Products Regulation, machinery may be also CE marked
under the Machinery Regulation.

When?
• The documentation should be issued by the manufacturer as soon as the product is placed on the
market.

Where?
• The documentation should be in line with the legislation of the country where the product was
placed on the market. However, when the product crosses the border to a different country, the
documentation will then have to be in line with the legislation of that country.

• The European Economic Area is an exception to this as it is a single market with free movement of
goods. This means that a product placed on the market and CE marked in any of these countries will be
automatically accepted in any of the other countries.

Why?
• Documentation is important because it contains the technical information that will allow the user to
safely use the product and claim conformity with the relevant legislation, when relevant.

How?
• It is usually required that relevant information is in an accompanying document. However, technical
information can be quite lengthy and there is a risk that it may be lost or associated with a different
product in the supply chain. To avoid this, manufacturers and legislation are increasingly adopting
digital methods (e.g. QR codes or digital data tags in the product) to improve traceability to the correct
information.

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Module I | I.2. Purchaser’s Responsibilities

At this stage of my Foundation Certificate training course, I found it useful

for me and my team to also read the LEEA User Guidance as it provides
useful information regarding the purchasing of lifting equipment.

If accessing this Course Handbook from a mobile or electronic device , select the “Download Resource”
button below to access LEEA’s User Guidance. Alternatively, you can access it through the relevant section
in the eLearning course at the LEEA App, or you can request a copy from your trainer.

185
Module I | I.3. Marking, Storage and Handling

Marking, Storage and Handling

Marking
Marking should be done by suitable means such as an identity plate, metal tab, textile
label, etc. Markings should be permanently attached or made by stamping directly into the
equipment in a low-stress area.

• When the marking is lost or worn away:

Additional information should be used to provide this information. It is therefore recommended that
the identification mark should also be put directly onto the equipment so that in the event of the
original means of marking becoming detached, the identity is not lost, and the other information can
be recovered from the related documentation.

• Marking Equipment with Temporary Information:

If a user wishes to mark the equipment with information that is likely to change (e.g. plant location
reference, date of examination, etc.) it is recommended that a separate tag is used instead of
remarking the original equipment material.

Storage and Handling

It is important to minimise the risk of damage and/or deterioration of lifting equipment whilst
it is in service, therefore storage is important. Some things to consider:

• Storage areas should be dry, free from contamination and pollution and not subjected to extremes of
temperature.
• Any exposed threads and machined surfaces (e.g. eyebolts) should be protected, handled with care
and stored carefully as these characteristics are critical to the operational integrity of the equipment.
• Equipment that is returned to stores when it is wet or has been in contact with other substances that
may cause deterioration should be handled with special care.

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Module I | I.3. Marking, Storage and Handling

• Solutions of chemicals will become more concentrated as the solvent evaporates, e.g. weak acids will
become strong acids. In these circumstances, the general advice is to clean and dry the equipment as it
is put into storage.
• Storage areas should be carefully controlled with no unauthorised access.

For organisations that are handling a large and varied amount of equipment, it may be more economical to
invest in a planned control system using a series of controlled stores, colour coding systems, etc.

“ Storage bins and racks etc. should be provided, and only the heavier,
more robust items should be allowed to lay on the floor. Requirements
for storing individual items are given in LEEA’s COPSULE.

Lifting Equipment Engineering Association “

COPSULE

On the advice of Osprey Lifting, Turbo Engineering has recently created its own storeroom for lifting
equipment that is used on its site. Racking and storage bins have been introduced and additional equipment
is currently being sourced.

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Module I | I.4. Maintenance and Inspection

Maintenance and Inspection

Maintenance
Lifting equipment should be properly maintained and safe to operate at all times. This is a
general legislative requirement globally.

Inspection
These are particularly important before issuing the equipment for use. The interim inspection
should be carried out by a Competent Person.

Current good practice requires pre-use inspections and interim inspections at suitable
intervals between the statutory thorough examinations. We explored these inspections in
section E: ‘Inspection and Examination’.

On completion of the thorough examination by a Competent Person, a report of thorough

examination should be issued. This should be kept with the records for the equipment.
It is also recommended that procedures be introduced and implemented by the organisation
to ensure that the manufacturer’s recommendations concerning regular maintenance are
carried out.

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Module I | I.4. Maintenance and Inspection Required Activity
!
The workers at Turbo Engineering have been instructed and trained to carry out pre-use inspections of all lifting
equipment before they use it for any lifting operation. They have also been instructed to carry out a post-use
inspection before returning the equipment to its appropriate storage area.

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

Why is a pre-use inspection important prior to using a piece of lifting equipment?

For what reasons are post-use inspections carried out as best

practice? (You may wish to refer to the section ‘Inspection and
Examination’ to help you with your answer).

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Module I | I.5. Training and Safe Use

Training and Safe Use

Training
All workers must receive suitable and sufficient training so that the health and safety of
themselves and others are protected at all times.

Formal training is the best way to achieve suitable and sufficient training but is widely
accepted that for most everyday activities, adequate training can be provided in-house by
more skilled and experienced workers.

The essential requirements for training provision are provided in national legislation, but also in international
conventions and regulations, such as those contained in ILO Convention C155 which states:

“…employers must give necessary instructions and training, taking into account of the functions and
capabilities of different workers.”

“ It is recommended that formal training be undertaken and a record kept

that an operative reached a satisfactory standard.

Lifting Equipment Engineering Association “

COPSULE

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Module I | I.5. Training and Safe Use

Summary
Training should always follow the following principles:

• Workers should be adequately trained in the safe use of the lifting equipment being used.

• Workers are to use only equipment for which they have received training or instruction and
to use it only in accordance with such training and instruction. (It should be noted that in
some countries this is a legal requirement).

• Workers shall be supplied with any operating instructions provided by the manufacturer or
supplier including updates relating to the use of the equipment.

Considering what you have learned so far in this Foundation course, we’d now like you to download the
‘Crane Operator Training Record’ that has been produced for Turbo Engineering. You will find this in the link
below.

This is used as a record of initial training and assessment but importantly, it is used for refresher training
sessions on a scheduled basis to ensure that the operator competencies and maintained and current.

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Module I | I.5. Training and Safe Use

If accessing this Course Handbook from a mobile or electronic device , select the “Download Resource”
button below to access the handout on Practical Assessment for Basic Operational Skills. Alternatively,
you can access it through the relevant section in the eLearning course at the LEEA App, or you can request
a copy from your trainer.

Safe Use
As we know from sections ‘Duties of Manufacturers’ and ‘Purchaser’s Responsibilities’, the
manufacturer is responsible for providing information about the safe use of the products they
are placing into the marketplace.

Key Point:
LEEA’s COSPULE guides the safe use of specific items of lifting equipment which is secondary
and supplementary to the top-level manufacturer’s instructions which should be used as the
primary information.

The general objective of good lifting practice is to ensure that the load is safe, and when lifted, it is as
secure in the air as it was on the ground.

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Module I | I.5. Training and Safe Use

LEEA Academy

LEEA offer a range of training courses on the inspection and examination of lifting equipment, with delivery
methods to suit your needs:

• Our UK Training Centre, onsite and via selected partners overseas

• Virtual Classroom (Face to Face with our instructor via webinar)
• eLearning

What’s Next?
Once you have successfully completed this Foundation Certificate, you will be able to progress to LEEA’s
specialist Diplomas to meet your training needs. Diploma courses currently include:

• LAC (Lifting Accessories)

• MLM (Manual Lifting Machines)
• PLM (Powered Lifting Machines)
• BGC (Bridge and Gantry Cranes)
• SUP (Supporting Structures)
• MOB (Mobile Cranes)
• OSC (Offshore Containers)

Further details can be found at https://leeaint.com/courses

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Module I | I.6. Disposal

Disposal
Disposal
Disposal of lifting equipment is the ultimate responsibility of the owner/user.

Steel components and machinery have scrap value, so this is the best form of disposal.
Crane components can sometimes be used in the manufacture of new machinery.
Particularly problematic are webbing and round slings which cannot be recycled. Another
issue with this type of sling is if they are not destroyed (cut up) before disposal, they can
often be mistakenly returned to service.

Key Point:
All ID labels and tags should be removed from items of lifting equipment prior to disposal.

“ Ensure sustainable consumption and production patterns. Achieve

the environmentally sound management of chemicals and all wastes
throughout their life cycle and significantly reduce their release to air,
water and soil to minimise their adverse impacts on human health
and the environment. Substantially reduce waste generation through
prevention, reduction, recycling and reuse.

United Nations
Sustainable Development: Goal 12
“

To join LEEA in creating a greener future, you can:

• Take action to reduce waste, conserve energy and support sustainable practices in your work.
• Always ensure that all lifting equipment is disposed of safely and responsibly.

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Module I | I.7. Reflective Learning Required Activity
!

Since the incident that took place with the incorrectly adjusted hoist brake in Module B, which resulted
in the tractor being dropped onto the trailer, Turbo Engineering has responded well to the actions
placed upon them by the enforcement agency.

With assistance from Osprey Lifting, they have provided training to staff in the safe use of lifting
equipment on site. This has included pre-use and interim inspections.

• Mike Menditt realised Danny Danger had not received adequate training and lacked a development plan
due to Mike’s busy schedule.

• Osprey Lifting provided additional training to Danny in managing lifting equipment in service.

• Danny showed significant improvement in his competencies following the training.

• Mike established a lifting equipment store in the factory and assigned Danny to manage all lifting
equipment on site, including the store, site locations, and service vehicles.

• Mike is pleased with Danny’s progress, recognising that the training has motivated Danny and improved
his understanding of the importance of safety and professionalism in preventing workplace accidents.

Other important information:

• An illustration of the store room is shown below. It has only recently been established and Danny is
working with Mike to ensure that they have everything they need to help them manage their lifting
equipment.

• Osprey Lifting carries out maintenance and repairs of the lifting appliances. They also carry out
Thorough Examinations of all lifting appliances using a technician who is not involved with the
maintenance.

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Module I | I.7. Reflective Learning Required Activity
!

Purchasing and Control of Lifting Equipment

Reflect about what you have learned throughout this section, then type your answer in the boxes
provided. These will be monitored by a member of LEEA Academy Training Team.

Danny is meeting with Karen Keeper for in-house training on the selection of
equipment for Turbo Engineering as he will work with her to advise on specifications
for new equipment required by the organisation. What are the key points that
Karen will need to discuss with Danny to help him understand the requirements
for providing a full specification for lifting equipment that needs to be purchased?
(Purchaser’s Responsibilities)

Danny is currently ensuring that all marking is present and correct on all the lifting
equipment at Turbo Engineering. List the requirements for marking lifting equipment
below to remind Danny what he should be looking for.

We looked at a near-miss incident earlier in Module ‘Manufacturing of Lifting

Equipment’ when a chain sling made from scrap lifting accessories was put together
in a hurry to “get the job done” which could have resulted in serious consequences.
So that this situation is prevented from happening again, what recommendations
would you make to Danny for the safe and effective disposal of lifting equipment?

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Module I | I.7. Reflective Learning Required Activity
!

I am Karen Keeper, the purchaser manager for Turbo Engineering. I have

recently purchased new chain slings. On this occasion I did not source
the slings from Osprey Lifting as they were much cheaper from a non-
LEEA member online.

When I received the slings there was no documentation included, so I

called the supplier but had no response. I decided to call Pete Hammer at
Osprey Lifting for advice.

I am Pete Hammer. I am the Works Engineer at Osprey Lifting Limited.

Karen, you should have received a manufacturer’s Certificate record of

test or a statement of conformity from your supplier for the chains you
purchased.

You should also have received the manufacturer’s instructions for the
safe use of the chains. The documentation should be issued by the
manufacturer as soon as the product is placed on the market. You should
check that this documentation and supporting information has not been
sent to you digitally, as this is common practice for some suppliers.

Remember that as a lifting equipment purchaser, Karen is responsible for ensuring that the equipment
is selected on its ability to perform safely under all foreseeable conditions of use, as determined by risk
assessment, and not just the price!

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Module I | I.7. Reflective Learning Required Activity
!

Crossword

We have put together a crossword to help you reinforce what you have learned so far. The clues are all
available from your learning this far into the course. The solution will be provided to you later.

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Module I | I.8. Knowledge Check Required Activity
!

If accessing this Course Handbook from a mobile or electronic device, click on the correct
answer and then select “Submit” to send in your response.

If using this Course Handbook in its printed version, simply tick the correct response using a pen.
Then refer back to your answers when it’s time for you to input your responses in the LEEA App.

Appointed persons who are identifying lifting equipment to be purchased must:

Be trained how to use any equipment they are to purchase

Ensure that lifting equipment is sourced at best available prices

Provide a specification with minimum performance requirements to the supplier

Marking requirements for lifting equipment are normally placed onto a metal tag identity
plate or label which is attached to the equipment. What other precautions should be taken
to ensure the equipment can be identified if its original identification label/tag/plate is lost or
becomes worn and illegible?

Markings should be placed directly onto the equipment

A colour code scheme may be used to help

Keep photographs for each piece of for identification purposes

Why is it important that lifting equipment is appropriately stored when not is use?

To prevent damage and deterioration

To prevent loss

To prevent unauthorised use

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Module I | I.8. Knowledge Check Required Activity
!
Before lifting equipment is responsibly disposed of, which of the following actions
must be taken?

It should be thoroughly examined for any defects

All identity tags, labels and plates are to be removed

It must have a ‘QUARANTINE’ label attached

On completion of a thorough examination of lifting equipment by a competent

person, what is issued to the owner/custodian of the equipment?

Certificate of test

Report of maintenance inspection

Report of a thorough examination

Interim inspection report

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Summary

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Summary | Key Messaging

Key Messaging
During this course, you have engaged in 9 modules of learning.

We now present to you a brief recap of the key messaging from the course that you can use in developing
your role within our industry.

Module A: LEEA’s Behaviours for a Safer World for Work

Remember LEEA’s Behaviours for a Safer World of Work:

Safety
• Look after yourself and others
• Follow your training
• Speak up and report it

Professionalism
• Carry out your work with care and diligence
• Lead by example
• Engage in effective communication

Competence
• Know what you can do
• Know what you can’t do
• Keep yourself up to date

Module B: Legislation and Regulations

Duty Holders
• Organisations and workers are all duty-holders.
• Different occupations have their own duty-holder responsibilities.

Module C: Managing Risk

Five Steps to Risk Assessment

• Identify the hazards
• Assess the risks
• Control the risks
• Record your findings
• Review your controls

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Summary | Key Messaging

Module D: Industry Relevant Definitions

Three Levels of Lifting Equipment Inspection

• Pre-use Inspection
• On-service Inspection
• The Thorough Examination

Competent Person Attributes

• Skills
• Knowledge
• Training
• Attitude
• Experience

Module E: Manufacturing of Lifting Equipment

Hierarchy of Risk Control Measures

• Elimination
• Substitution
• Engineering Controls
• Administration Controls
• PPE

Manufacturing Conformity Documents

Depending on the standard worked on:

• Certificate of Test
• Statement of Conformity
• Manufacturer’s Certificate
• Attitude
• Experience

Module F: Materials and Properties

There are several suitable materials used in the lifting equipment industry. Their main characteristics are:

• Strength
• Ductility
• Shock Resistance
• Wear Resistance
• Chemical Resistance

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Summary | Key Messaging

• Resistance to Extreme Temperatures

• Corrosion Resistance

Module G: Lifting Accessories

Accessories can be:

• Chain slings
• Eyebolts
• Shackles

Module H: Lifting Appliances

Lifting appliances can be:

• Electric Chain Hoists

• Portal Cranes

Module I: Purchasing and Control of Lifting Equipment

• ID Plate, metal tab or label ID

• Permanent marker on equipment in case of loss or wear
• Other user markings on additional tabs or label

Report of Thorough Examination

• Issued by a competent person following a thorough examination
• Must be retained as part of lifting equipment records to include records of any tests

Responsibilities of Lifting Equipment Purchasers

• Understand the equipment
• Environmental conditions in use
• Duty requirement
• Applicable legislation/standards
• Competence/training for users

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Summary | Key Messaging

Crossword Solutions

Solution to Crossword 1

205
Summary | Key Messaging

Crossword Solutions

Solution to Crossword 2

206
Summary | Feedback Required Activity
!
Feedback
Before proceeding with your Personal Commitment and taking your online course assessment, we
would like to gather your feedback.

Your input is essential to us and will help improve our training programs for you and others in the
industry.

After submitting your feedback, you can continue to your Personal Commitment in this section.

In the next module, we will offer guidance for your online assessment.

If accessing this Course Handbook from a mobile or electronic device, simply select the “Submit Feedback”
button below to fill in your responses.

If using this Course Handbook in its printed version, you can either use your phone to scan the QR code on
the page which will take you to the feedback survey, access the correspondent section of the elearning
course on the LEEA App, or contact your trainer for further assistance.

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Summary | Personal Commitment Required Activity
!
Personal Commitment
Thank you for your feedback!

During the introduction to this course, we listed a number of required activities that are to be completed for
successful completion of this course, one of which was the Personal Commitment.

Your personal commitment should focus on at least one of LEEA’s Behaviours for a Safer World of Work:

• Safety
• Competence
• Professionalism

The illustration on the next page provides an example of how to write a personal commitment. In this case,
the individual has committed to reading the LEEA series and recording their findings in their CPD record
once a week over a period of 6 weeks, to be repeated twice a year.

When considering your personal commitments, we encourage you to review LEEA’s Behaviours for a Safer
World of Work and our mission. Here’s a reminder of that mission:

“ Our mission is: Lifting and height safety industries which have
eliminated accidents, injuries and fatalities.

Lifting Equipment Engineering Association “

Mission Statement

If accessing this Course Handbook from a mobile or electronic device, simply select the “Download
Resource” button below to access a digital copy of the Personal Commitment document.

If using this Course Handbook in its printed version, you can fill in your responses on the template provided
on the next page.

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Summary | Personal Commitment Required Activity
!

209
Summary | Assessment Information

Assessment Information
The online assessment consists of 50 multiple-choice questions that directly align with the assessment
criteria you have seen at the beginning of each of the learning modules in this course. You will have 50
minutes to complete the assessment.

• Once you have successfully passed the Foundation Certificate assessment, you will be able to study
any of LEEA’s diploma-level training courses.

• Be sure to follow the assessment rules at all times so that you do not risk being invalidated or removed
from the session. The rules will be provided to you before you start your assessment session.

Good luck and remember that LEEA staff are available to you should you require any assistance in
accessing your assessment.

academysupport@leeaint.com

LEEA

Accessing Your Assessment

Once you have finished the next, and final section of this course, and all required activities have been
completed, your online assessment will be activated in the LEEA Academy App.

You will have 30 days in which to complete your online assessment.

To access your assessment in the LEEA Academy App, click the 3 menu dots °°° in the top right corner of
the screen and go to ‘My Assessments’.

Your assessment will be visible here with the expiry date shown below.

Please ensure you complete it within the allocated 30 days.

Important Notes
Before taking your assessment:

• Close all Apps that may have notification pop-ups.

Closing pop-ups during your assessment will result in the system assuming you are trying to use
another program and it will exit you from the assessment.

• Check screen and camera permissions.

Ensure your screen share and camera permissions are on.

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Summary | Assessment Information and Thank You

Exited assessments can only be unlocked by contacting LEEA staff via email to:

assessments@leeaint.com

Thank You
During this course, you will have gained essential underpinning knowledge of relevant legislative
requirements, standards and best practices, in addition to specific technical information regarding
common types of lifting equipment, the materials and the science behind their development and
verification.

We thank you for choosing LEEA Academy for your occupational training requirements and hope that you
have enjoyed the experience we have created to help you maximise your learning throughout your time with
us.

Remember that learning doesn’t stop here.

“ The more I learn, the more I realise how much I don’t know.

Albert Einstein “
(1979 - 1955)

Thank you, and good luck with your

online assessment!

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