Monday Tech Talk – Lifting Machinery

Lifting operations take place every day across construction sites, fabrication yards, mines, warehouses, and engineering workshops. Whether it’s hoisting a steel beam, manoeuvring heavy equipment, or lifting personnel for inspection work, the reliability and compliance of lifting machinery is non-negotiable. Unlike many other tasks, lifting failures rarely offer second chances. The systems, standards, and procedures we follow exist for one reason: to ensure predictable, controlled lifting in environments where unpredictability can cost lives.

This article explores the legal framework shaping lifting operations in South Africa, the design requirements for lifting machinery, the testing and inspection obligations, and the strict controls surrounding man-cages, manual lifting devices, and earthmoving equipment used for lifting.

Legal Framework: The Foundation of Safe Lifting

Safe lifting begins with the law. In South Africa, lifting machinery is governed primarily by:

• The Occupational Health and Safety Act (OHS Act), 1993
• The Driven Machinery Regulations (DMR), 2015

These regulations establish clear requirements for:

• Design and engineering
• Inspections and examinations
• Test certification and documentation
• Operator competency

This framework ensures lifting machines operate with consistency, reliability, and traceability. Without it, lifting operations would be unpredictable — and dangerous.

Engineering, Design, and Construction Requirements

Every lifting machine — whether mechanically powered or manually operated — must be designed and constructed to recognised technical standards.

Key design elements include:

• Structural integrity based on engineering principles
• Material strength and durability
• Certified load-bearing components
• Built-in safety devices and fail-safe mechanisms

A lifting machine is only as safe as its engineering. Compliant design prevents catastrophic failures under load, impact, or dynamic movement.

Safe Working Load (SWL): The Most Important Label on Any Lifter

Every lifting machine or device must clearly display:

• Its Safe Working Load (SWL), or
• A load chart if capacity varies by configuration

This information must be visible to the operator at the point of use. The SWL is not an optional sticker — it prevents overloading, structural failure, and collapse. When SWL markings are missing, assumptions take their place, and assumptions lead to accidents.

Mandatory Testing, Inspections, and Recordkeeping

Under the Driven Machinery Regulations, lifting equipment must undergo:

• Annual performance tests and examinations by a certified Lifting Machinery Inspector (LMI)
• Six-monthly inspections of safety mechanisms, hooks, ropes, and slings by a competent person

Documentation must include:

• Test certificates
• Examination and inspection records
• Repair and modification histories

These records must be kept on site and available for inspection at any time. Compliance is not just a responsibility — it is legal proof that equipment remains safe to operate.

Man-Cages: Strictly Controlled, Exceptional Use Only

Lifting people is far riskier than lifting materials. For that reason, man-cages are among the most tightly regulated lifting devices.

Personnel may only be lifted in a man-cage if:

• The cage is designed and certified to a SANS standard
• A task-specific risk assessment is completed
• A Department of Labour inspector approves the cage
• The Department of Labour is notified for each site

Every site requires its own approval because conditions differ — machines, operators, terrain, wind exposure, and surroundings all influence risk.

Man-cages are not routine equipment. They are exceptional-use solutions and should only be deployed when no safer alternative exists.

Why MEWPs Are Preferred Over Man-Cages

SANS 583:2015 makes it clear: Mobile Elevating Work Platforms (MEWPs) are the preferred system for lifting people.

Why?

• They are engineered specifically for personnel lifting
• They have integrated stability and fall protection
• Operators control movement from within the platform
• Their operation is predictable and designed for work at height

Man-cages suspended from cranes lack these engineered controls, making them unsuitable for routine work.

MEWPs = designed for people.
Man-cages = emergency or exceptional use only.

Hand-Powered Lifting Devices: Chain Blocks, Lever Hoists, and Ratchet Hoists

Manual lifting devices may be simple, but they are powerful tools capable of lifting tonnes of material. With that power comes the same compliance requirements as motorised lifting machinery.

Hand-powered devices must undergo:

• Annual load testing by a certified LMI
• Pre-use inspections
• Strict checks for chain damage, bent hooks, missing safety latches, and modifications

Incorrect or poorly maintained manual equipment can fail violently under load, causing severe injuries or fatalities.

Structural Support: The Hidden Weak Link

Even compliant equipment becomes unsafe if suspended from a weak structure.

A 2-ton chain block is dangerous when hooked to a beam rated for only 1 ton. Operators must verify:

• Structural capacity
• Load path
• Support integrity

This is a commonly overlooked hazard and one of the leading causes of lifting-related failures. Structural suitability is as important as the lifting device itself.

Earthmoving Machines Are Not Lifting Machines — Unless They Comply

Earthmoving machines like TLBs and excavators are designed for digging, loading, and trenching — not lifting. For that reason, the Driven Machinery Regulations exclude them from the definition of lifting machinery.

However, in practice, many sites use excavators for lifting tasks due to convenience or necessity.

When they are used for lifting, the law requires that they comply with the same safety standards as cranes or hoists.

This includes:

• Annual load testing
• Six-monthly inspections
• Certified hooks and attachment points
• Access to manufacturer-approved load charts

Using an excavator without a load chart is dangerous — the machine’s lifting ability varies dramatically depending on boom position, reach, ground conditions, and slew angle.

Load Charts: Eliminating Guesswork

Load charts show safe lifting limits for specific machine configurations.

They provide essential information on:

• Maximum load at different boom angles
• Capacity at various outreach distances
• Hydraulic limits and stability limits
• Safe lifting positions relative to the machine

Without a load chart, operators cannot accurately determine safe working limits, dramatically increasing the risk of tip-over or mechanical overload.

Bringing It All Together: What Safe Lifting Really Means

Safe lifting relies on multiple layers of control:

• Correct equipment selection
• Engineering-compliant design
• Mandatory inspections and testing
• Clear SWL markings
• Competent, trained operators
• Proper attachment to structurally sound systems
• Use of MEWPs for personnel wherever possible

When these elements align, lifting becomes a controlled, predictable, and professional process. When shortcuts appear — undocumented equipment, missing SWL labels, uncertified hooks, or improvised lifting methods — incidents follow quickly.

 

Lifting machinery — from cranes to chain blocks, MEWPs to man-cages — exists within a strict legal and technical ecosystem for one purpose: protecting people. When the standards are respected, lifting operations are safe, efficient, and professional. When they’re ignored, equipment fails, structures collapse, and lives are put at risk.

Compliance is not an administrative burden. It is a safety asset.