Audience: project managers, APs/Lift Supervisors, site engineers
Goal: plan and execute lifting operations that are safe, compliant, and predictable—with documentation that stands up to audit.

Note: This article is guidance only. Always follow your client’s procedures and applicable law/standards (e.g., LOLER/PUWER and BS 7121 in the UK) and use a competent Appointed Person (AP) for planning and supervision.

What is an “engineered” lift plan?

All lifting operations require planning. A lift is typically classed as engineered when the risk/complexity demands calculations, drawings and controls beyond a “routine” pick. Examples include unusual geometry, restricted headroom, high capacities, tandem lifts or sensitive interfaces (rail, highways, public, live plant, clean areas).

An engineered plan will normally include: load/rigging calculations, crane selection and configuration, ground bearing pressure (GBP) checks, swept-path drawings, exclusion zones, comms, weather limits and an emergency strategy.

When do you need one?

Use an engineered plan whenever one or more of the below apply:

• Near-capacity lifts or long radii close to chart limits
• Unknown/variable load weights or moving centres of gravity (CoG)
• Tandem/dual crane or multi-hoist lifts
• Restricted headroom or obstructions (beams, pipework, live conveyors)
• Suspended slabs/basements (outriggers on structures → GBP calc & verification)
• Pick-and-carry or travelling with load
• Public interface: over footways/roads, adjacent rail, utilities corridors
• Sensitive environments: live production, ATEX/clean areas, hospitals, schools
• Unusual rigging: spreader frames, lifting beams, equalising gear, man-baskets*
• Adverse ground: buried services, made ground, slopes, voids, high water table
• Weather-critical items: large panels, cladding, glazing with sail area

* Lifting persons requires additional controls and may be prohibited unless no safer alternative exists.

If in doubt, treat it as engineered and engage an AP early.

Who does what? (Dutyholders)

• Appointed Person (AP): Plans the lift, produces/approves the lift plan and risk assessment, appoints the team, ensures resources/controls.
• Lift Supervisor: Leads the operation on site, briefs RAMS/plan, manages permits/exclusion zones, stops the lift if conditions change.
• Slinger/Signaller (Banksman): Selects and attaches rigging, confirms CoG/witness marks, controls the lift via signals/radios.
• Crane/Hoist Operator: Operates equipment within the plan and capacity charts, reports concerns, stops if unsure.
• Temporary Works/Structural Engineer (as required): Verifies GBP and slab/capping beam capacity, designs mats/spreaders.

Competence is evidenced via CPCS/NPORS cards and relevant manufacturer training, with experience logged.

What must the engineered plan include?

1) Scope & survey

• Description of load(s), lift path and end positions
• Site survey (levels, obstructions, overheads, undergrounds, access/egress)
• Interfaces (public highway, rail, production areas, neighbours)

2) Load & rigging

• Verified load weights (drawings, weigh tickets or calculation)
• CoG position & stability assessment (sketch)
• Rigging method: slings, angles, spreader beams/frames, shackles, turnbuckles
• Rigging list with WLLs, certificates and factor of safety

3) Equipment selection

• Crane/gantry/hoist type and configuration (main boom, jib, counterweights)
• Capacity chart extracts at radius & configuration used
• Weather limits (wind, temperature) and sail-area assessment
• Radios/hand signals; backup comms

4) Ground bearing & mats

• Outrigger/wheel loads and GBP calculations
• Verification of ground or structural capacity (trial pits, drawings, engineer sign-off)
• Mat/spreader design and placement drawing

5) Drawings & controls

• Plan/elevation with swept paths, radii, heights and exclusion zones
• Pick/set positions; staging/laydown areas
• Permit matrix (hot works, highways, roof access, MEWP, confined space)
• Public protection (hoarding, lookouts, banksmen, road closures if needed)

6) Procedure & sequencing

• Step-by-step method statement (pre-lift → rigging → test lift → travel → set)
• Tandem lifts: load share, primary/secondary crane, signal protocol
• Contingencies: lost comms, weather spike, equipment fault, abort and recover
• Emergency plan: rescue routes, first aid, contact tree

7) Team & briefings

• Named personnel and roles (AP, Supervisor, Slinger/Signaller, Operator)
• Competence evidence and medical fitness where required
• TBT/briefing sheet with sign-in and language needs

8) Records

• Inspection/Thorough Examination (LOLER) certificates for crane & rigging
• Daily/shift pre-use checks, anemometer readings, weather logs
• Lift log and debrief (lessons learned)

Inputs you need before design

• Latest GA/sections, structural details for slabs/edges/capping beams
• Utility plans/scan results and no-dig zones
• Delivery vehicle sizes/turning paths; crane set-up footprint
• Manufacturer data for the load (lifting points, allowable angles, fragile areas)
• Site constraints: black-out times, noise/dust limits, public interface windows

On-the-day flow (one-page checklist)

1. Permit board updated; weather within limits; anemometer working
2. Ground/mats verified; exclusion zones/barriers set; signage up
3. RAMS & plan briefed; team signed in; radios checked; rescue plan known
4. Rigging inspected/certified; sling angles acceptable; witness marks applied
5. Test lift: 100–200 mm off ground to verify balance/rigging/deflection
6. Travel path clear; banksman positions agreed; public protection in place
7. Lift executed to plan; no deviations without AP authority
8. Load set; rigging removed safely; area made safe; debrief recorded

Common failure modes (and how to avoid them)

• Wrong weight/CoG → Verify from multiple sources; do a test lift close to ground.
• Ground failure → Do GBP calcs; prove slab capacity; use adequate mats; avoid trenches/voids.
• Sling angle overload → Calculate forces; keep angles ≥60° where possible; use spreaders.
• Wind/sail area underestimated → Use manufacturer data; set conservative limits; monitor gusts.
• Conflicting signals/radios → Appoint a single signaller; test comms; agree handover protocol.
• Drift from plan → Supervisor authority to STOP; escalate to AP; revise and re-brief.

Tandem lifts: extra rules of thumb

• Appoint lead crane and lead signaller; practise comms.
• Define load share and allowable divergence (e.g., ±10%).
• Keep cranes on similar boom angles where practical; avoid side load.
• Instrumentation or load cells if share is critical.
• Strict, slow, incremental moves with agreed stop points.

Documentation pack (what the auditor expects)

• Signed engineered lift plan & risk assessment
• Capacity charts, GBP calcs, drawings with exclusion zones
• LOLER/PUWER certificates; rigging certificates & register
• Permits and traffic management/road closure approvals
• Briefing/TBT sheets with signatures & date/time
• Weather logs/anemometer readings; lift log & debrief

Red lines—STOP the lift if:

• Wind exceeds the limit or gusting unpredictably
• Load behaves unexpectedly (rotation, snag, instability)
• Communication is lost or conflicting
• A person or vehicle breaches the exclusion zone
• Any equipment fault, alarm or chart exceedance is suspected

Final word

Engineered lifting isn’t about paperwork—it’s about predictability. Get the inputs right, prove the ground, choose the right gear, and brief the team. Do that, and the lift looks boring to spectators—and that’s exactly what you want.

Need editable templates (lift plan, rigging list, GBP calc, TBT)? Email [email protected] and we’ll send a pack aligned to your scope.