12 Aug Rigging and Hoisting – JSA

Rigging and Hoisting Job Safety Analysis (JSA)

Job / Task

Selection, inspection, attachment, use, and removal of rigging and hoisting equipment for lifting, moving, positioning, and setting materials, equipment, and components using cranes, hoists, chain falls, lever hoists, or other approved lifting devices.

Purpose

This Job Safety Analysis (JSA), also known as a Job Hazard Analysis (JHA), identifies hazards associated with rigging and hoisting and establishes safe work practices and controls to prevent dropped loads, rigging failure, struck-by, caught-between, crushing, pinch-point, and other material-handling and lifting injuries.

Personnel Qualifications

Rigging and hoisting shall be performed by trained, qualified, competent, or authorized personnel as required by the equipment, task, and applicable regulations. Qualified riggers and signal persons shall be used when required.

Personnel shall:

• Understand load weight, center of gravity, lift points, rigging configurations, sling angles, and rated capacities.
• Know the limitations and proper use of slings, shackles, hooks, eyebolts, hoists, spreader beams, lifting beams, and other rigging hardware.
• Inspect rigging and hoisting equipment before use and remove defective equipment from service.
• Protect slings from sharp edges, excessive heat, chemicals, and other damaging conditions.
• Understand standard signals and communication methods used for the lift.
• Recognize suspended-load, fall-zone, pinch-point, and line-of-fire hazards.
• Identify overhead power lines and other obstructions affecting the lift.
• Stop work whenever load weight, rigging capacity, lift points, equipment condition, communication, or load stability is uncertain.

Required PPE

PPE shall be selected based on the rigging and hoisting task, material, equipment, and work environment and may include:

• Hard hat.
• Safety glasses with side protection.
• Work gloves suitable for handling wire rope, chain, slings, and rigging hardware.
• Safety footwear appropriate for material-handling and crushing hazards.
• High-visibility apparel where mobile equipment or traffic hazards exist.
• Hearing protection where required.
• Fall protection where employees are exposed to applicable fall hazards.
• Additional task-specific PPE identified by the hazard assessment.

JSA – Job Steps, Hazards, and Controls

Step 1 – Plan the Lift

Potential Hazards

• Unknown load weight.
• Incorrect rigging selection.
• Load instability.
• Dropped load.

Required Controls

• Determine the load weight, dimensions, center of gravity, lift points, travel path, and final placement before rigging.
• Determine the lifting device capacity at the intended configuration.
• Identify whether a critical-lift or engineered-lift plan is required by company, client, or site procedures.
• Evaluate environmental conditions, overhead obstructions, ground conditions, and nearby work.
• Conduct a pre-lift briefing appropriate to the complexity and hazards of the lift.

Step 2 – Determine Load Weight and Center of Gravity

Potential Hazards

• Overloaded rigging.
• Unexpected load rotation.
• Unbalanced load.

Required Controls

• Use drawings, shipping documentation, equipment data, calculations, or another reliable method to determine load weight.
• Do not guess the weight of a load when capacity is uncertain.
• Identify the approximate center of gravity before selecting lift points.
• Position lifting connections so the hook is above the center of gravity where practical.
• Reevaluate the rigging arrangement if the center of gravity is uncertain.

Step 3 – Select Rigging Equipment

Potential Hazards

• Underrated sling or hardware.
• Incompatible components.
• Rigging failure.

Required Controls

• Select slings and hardware with adequate rated capacity for the load and hitch configuration.
• Account for sling-angle effects on sling tension.
• Use rigging designed for the environment, including temperature, chemicals, and sharp edges.
• Use only compatible hooks, shackles, eyebolts, links, and attachments.
• Do not exceed manufacturer-rated capacities.

Step 4 – Inspect Slings

Potential Hazards

• Broken wire rope.
• Damaged synthetic sling.
• Stretched chain.
• Rigging failure.

Required Controls

• Inspect slings before use for damage and required identification.
• Check wire-rope slings for broken wires, kinking, crushing, birdcaging, corrosion, and damaged fittings.
• Check synthetic slings for cuts, tears, abrasion, heat or chemical damage, broken stitching, and damaged fittings.
• Check alloy-chain slings for stretched, bent, cracked, gouged, or worn links and components.
• Remove defective or unidentified slings from service as required.

Step 5 – Inspect Rigging Hardware

Potential Hazards

• Shackle failure.
• Hook failure.
• Damaged lifting device.

Required Controls

• Inspect shackles, hooks, eyebolts, links, rings, spreader beams, lifting beams, and other hardware before use.
• Check for cracks, deformation, excessive wear, damaged threads, missing parts, or illegible capacity markings.
• Verify hook safety latches are present and functional where required.
• Use the correct shackle pin and do not substitute bolts or makeshift components.
• Remove defective hardware from service.

Step 6 – Inspect Hoisting Equipment

Potential Hazards

• Hoist failure.
• Brake failure.
• Damaged chain or wire rope.
• Unexpected load movement.

Required Controls

• Inspect chain falls, lever hoists, powered hoists, and other lifting devices before use.
• Verify hooks, chains, wire ropes, controls, brakes, limit devices, and attachments are in safe condition.
• Confirm the hoist is properly supported from a rated anchorage or structure.
• Do not use a hoist with an unknown or inadequate supporting structure.
• Remove defective equipment from service.

Step 7 – Prepare the Load

Potential Hazards

• Sharp edges.
• Loose components.
• Unexpected movement.
• Pinch points.

Required Controls

• Secure loose parts before lifting.
• Identify and protect sharp edges that could damage slings.
• Remove or secure materials that could fall from the load.
• Use blocking or cribbing where necessary to allow safe rigging attachment.
• Keep hands and body parts clear of pinch points while preparing the load.

Step 8 – Attach Rigging to the Load

Potential Hazards

• Pinched hands.
• Improper hitch.
• Side-loaded hardware.
• Load shift.

Required Controls

• Use designated lifting points when provided and verify they are suitable for the intended load.
• Apply the selected hitch correctly and position slings to prevent slipping.
• Do not knot, twist, or shorten slings using unauthorized methods.
• Load shackles, hooks, and eyebolts in the direction for which they are designed.
• Keep fingers clear as slack is removed from the rigging.

Step 9 – Protect Slings from Edges

Potential Hazards

• Sling cutting or abrasion.
• Dropped load.

Required Controls

• Install suitable edge protection where slings contact sharp or abrasive surfaces.
• Ensure padding remains in place as rigging is tensioned.
• Use protection compatible with the sling type and load.
• Do not rely on improvised protection that can shift or fail.
• Recheck sling condition after the lift when significant edge loading occurred.

Step 10 – Establish Communication

Potential Hazards

• Conflicting signals.
• Unexpected hoist movement.
• Operator unable to see load.

Required Controls

• Designate a signal person when required.
• Agree on hand signals, radio communications, or other methods before lifting.
• Use standard signals unless an alternate method is appropriate and understood.
• Only one designated person shall direct normal load movement; anyone may give an emergency stop signal.
• Stop movement immediately if communication is lost or unclear.

Step 11 – Establish the Exclusion Zone

Potential Hazards

• Struck-by load.
• Crushing.
• Personnel beneath suspended load.

Required Controls

• Control access to the lifting and landing areas.
• Keep unauthorized personnel outside the fall zone and load path.
• Do not permit employees beneath suspended loads except where specifically allowed by applicable requirements.
• Keep personnel clear of areas where the load could swing, shift, tip, or fall.
• Identify and control pinch and crush points before hoisting.

Step 12 – Take Up Rigging Slack

Potential Hazards

• Rigging snag.
• Pinch points.
• Unequal loading.
• Load movement.

Required Controls

• Apply tension slowly and evenly.
• Observe slings and hardware as they seat under load.
• Keep hands and body parts away from tensioned rigging.
• Stop if rigging shifts, binds, twists, or loads unevenly.
• Correct the rigging arrangement before proceeding.

Step 13 – Perform a Test Lift

Potential Hazards

• Unbalanced load.
• Rigging movement.
• Brake failure.
• Unexpected rotation.

Required Controls

• Raise the load only a few inches or enough to verify balance, rigging security, and hoist response.
• Confirm the load is stable and rigging remains properly seated.
• Verify brakes and lifting equipment hold the load.
• Lower and correct any unsafe condition before continuing.
• Do not proceed with an unstable or questionable load.

Step 14 – Hoist and Move the Load

Potential Hazards

• Dropped load.
• Load swing.
• Shock loading.
• Collision.

Required Controls

• Hoist smoothly and avoid sudden starts, stops, or shock loading.
• Keep the load as low as practical while maintaining required clearance.
• Monitor rigging and load behavior continuously.
• Do not drag loads sideways with hoists unless the equipment is specifically designed and approved for that use.
• Maintain a clear load path and stop the lift if conditions change.

Step 15 – Control the Load with Tag Lines

Potential Hazards

• Load rotation.
• Entanglement.
• Struck-by hazard.

Required Controls

• Use tag lines or other load-control methods when necessary and safe.
• Use nonconductive tag lines where electrical hazards may exist.
• Never wrap a tag line around the hand, arm, waist, or other body part.
• Maintain enough distance to remain outside the load’s fall and crush zones.
• Do not attempt to stop an uncontrolled swinging load by hand.

Step 16 – Position and Land the Load

Potential Hazards

• Crushing.
• Pinch points.
• Unstable landing surface.
• Rigging trapped beneath load.

Required Controls

• Prepare the landing area before lowering the load.
• Use blocking or cribbing as needed to provide stable support and permit safe rigging removal.
• Keep hands, feet, and body parts out from beneath the load.
• Use tag lines or tools to position the load rather than placing employees in pinch points.
• Confirm the load is stable and fully supported before releasing rigging tension.

Step 17 – Release and Remove Rigging

Potential Hazards

• Stored tension.
• Rigging shift.
• Falling hardware.
• Pinched fingers.

Required Controls

• Release tension gradually after confirming the load is secure.
• Keep personnel clear of rigging that may shift or spring free.
• Remove slings and hardware without placing hands under unsupported materials.
• Inspect rigging after use for damage.
• Tag and remove damaged equipment from service.

Step 18 – Store Rigging Equipment

Potential Hazards

• Damage from improper storage.
• Trip hazards.
• Future use of damaged rigging.

Required Controls

• Clean rigging as appropriate and store it in designated locations.
• Keep slings off the ground and protected from moisture, chemicals, sunlight, sharp edges, and excessive heat as applicable.
• Separate damaged or quarantined equipment from serviceable rigging.
• Maintain required inspection or identification records.
• Do not leave rigging where it creates trip or struck-by hazards.

Step 19 – Respond to Unsafe or Uncontrolled Load Movement

Potential Hazards

• Dropped load.
• Swinging load.
• Rigging failure.
• Crushing.

Required Controls

• Do not attempt to catch, restrain, or physically stop an uncontrolled load.
• Warn personnel and clear the fall zone.
• Use the emergency stop signal when necessary.
• Lower the load to a safe location when possible.
• Inspect the rigging, hoisting equipment, and load arrangement before resuming work.

General Safe Work Requirements

• Rigging and hoisting shall be performed only by personnel trained and qualified for their assigned duties.
• The load weight and center of gravity shall be known or reliably determined before lifting.
• Rigging and hoisting equipment shall not be loaded beyond its rated capacity.
• Sling angles and hitch configurations shall be considered when determining rigging capacity.
• Rigging shall be inspected before use, and defective equipment shall be immediately removed from service.
• Slings shall be protected from sharp edges and other conditions that could damage them.
• Loads shall be attached only to suitable lift points or by rigging methods capable of safely supporting and controlling the load.
• Employees shall remain clear of suspended loads, fall zones, load paths, and pinch or crush points.
• Communication shall be established before lifting, and movement shall stop when signals are unclear or communication is lost.
• Tag lines or other load-control methods shall be used when necessary to prevent uncontrolled rotation or movement.
• Loads shall be landed on stable support before rigging is released.
• Work shall stop whenever load weight, rigging capacity, lift points, equipment condition, communication, or load stability is uncertain or unsafe.

Training

Employees involved in rigging and hoisting shall receive training appropriate to their duties. Training shall include rigging inspection, rated capacities, sling types and hitches, sling-angle effects, hardware selection, center-of-gravity principles, lift points, edge protection, hoist inspection, load control, signaling, tag-line use, suspended-load and fall-zone hazards, pinch-point avoidance, critical-lift requirements where applicable, and stop-work expectations.

References

• OSHA 29 CFR 1926.251 – Rigging Equipment for Material Handling.
• OSHA 29 CFR 1926 Subpart CC – Cranes and Derricks in Construction, where applicable.
• OSHA 29 CFR 1926.1419 through 1926.1422 – Signals, where applicable.
• OSHA 29 CFR 1926.1425 – Keeping Clear of the Load, where applicable.
• Applicable manufacturer instructions, sling and rigging identification, hoisting procedures, lift plans, and site requirements.