10 Oct Come-A-Longs, Lever Hoists, and Chain Hoist Safety

Come-A-Longs, Lever Hoists, and Chain Hoist Safety

Hand-operated hoists, including come-a-longs, lever hoists, and manual chain hoists, are commonly used to lift, position, tension, and move materials or equipment. Typical applications include positioning pipe or plate, moving machinery, installing equipment, and supporting maintenance and repair work.

Although these devices are relatively simple to operate, improper selection or use can result in dropped loads, equipment failure, struck-by or caught-between injuries, and fatalities.

Note: The term “coffin hoist” is sometimes used informally for certain lever or chain hoists, but lever hoist or manual chain hoist is preferred terminology.

Inspect Before Use

Inspect the hoist before each use and according to the manufacturer’s requirements. Do not use a hoist that is damaged, defective, or suspected of having been overloaded.

Check for:

• Bent, twisted, cracked, or stretched chain links;
• Excessive chain wear, corrosion, or damage;
• Bent, twisted, cracked, or excessively opened hooks;
• Damaged or missing hook safety latches, where provided;
• Bent or damaged operating handles;
• Damaged ratchets, pawls, gears, or braking mechanisms;
• Kinked, frayed, bird-caged, or otherwise damaged wire rope on applicable devices;
• Missing or illegible capacity markings;
• Unusual noises, binding, slipping, or stiff operation; and
• Any cracked, bent, distorted, worn, or broken component.

Remove defective equipment from service immediately and have it inspected or repaired by qualified personnel. Do not make unauthorized repairs or modifications.

Know the Load and Hoist Capacity

Before lifting, determine the approximate weight of the load and verify that it does not exceed the hoist’s rated load capacity.

• Never exceed the manufacturer’s rated capacity.
• Never rely on appearance or guesswork when the load’s weight is uncertain.
• Do not use two or more hoists to lift a load exceeding the capacity of an individual hoist unless the lift has been specifically planned and the load distribution is controlled.
• Do not assume an older or damaged hoist can safely handle its marked capacity; questionable equipment must be removed from service.
• Never use a hoist unless its rated capacity is clearly identified.

The rigging equipment, attachment points, and supporting structure must also be capable of safely supporting the anticipated load.

Never Use a Cheater Bar

Operate the hoist only with the handle, hand chain, or controls provided by the manufacturer.

Never:

• Add a pipe or “cheater bar” to a hoist handle;
• Extend or modify the operating lever;
• Have multiple employees apply excessive force to the operating mechanism; or
• Use powered equipment to operate a manually operated hoist unless specifically permitted by the manufacturer.

Difficulty operating a hoist may indicate overloading, equipment damage, improper rigging, or another unsafe condition. Stop and determine the cause rather than applying additional force.

Rig the Load Correctly

Before applying tension:

• Verify that the supporting structure and attachment point can safely support the load.
• Use properly rated slings, shackles, and other rigging equipment.
• Seat hooks properly in the bowl or saddle of the hook.
• Never point-load the tip of a hook.
• Position the hoist so the load is applied in a straight line from hook to hook.
• Ensure the load is balanced and controlled before lifting.
• Keep chains and wire ropes free of twists, knots, and kinks.

Never use the hoist’s load chain or wire rope as a sling by wrapping it around the load.

Do not allow the load chain to bend, drag, or bear against corners, sharp edges, or obstructions.

Lift Smoothly and Maintain Control

Apply the load gradually and smoothly. Avoid sudden movements that can create shock loading.

• Take up slack slowly before beginning the lift.
• Make a short test lift to verify that the load is balanced and properly secured.
• Do not jerk, bounce, or rapidly accelerate the load.
• Prevent uncontrolled swinging or rotation.
• Never side-pull unless the hoist is specifically designed and approved for that purpose.
• Maintain secure footing and a stable working position while operating the hoist.

Position yourself so that a slipping hand, equipment failure, or unexpected load movement will not place you in the line of fire.

Stay Clear of Suspended Loads

A suspended load can fall or shift without warning.

• Never stand, walk, or work beneath a suspended load.
• Never allow another employee to enter beneath a suspended load.
• Keep hands, feet, and other body parts away from pinch points and areas where the load could shift or settle.
• Establish an exclusion area when necessary.
• Never use a material hoist to lift or support people unless it is specifically designed and approved for personnel lifting.
• Do not leave a suspended load unattended unless the equipment and application are specifically designed and controlled for that condition.

Whenever practical, lower the load to a stable surface or adequately support it before beginning work.

Storage and Maintenance

After use:

• Lower and remove the load before storing the hoist.
• Store hoists in a clean, dry location where chains and components will not be damaged.
• Keep chains properly lubricated according to manufacturer instructions.
• Protect equipment from corrosion, chemicals, welding spatter, excessive heat, and physical damage.
• Ensure required periodic inspections and maintenance are completed and documented as applicable.

Remember

Hand-operated hoists are safe only when properly selected, inspected, rigged, and operated within their rated capacity. Never overload a hoist, use a cheater bar, wrap the load chain around a load, shock-load the equipment, or place yourself beneath a suspended load.