HK Loadshifting Operator (CIC) cheat sheet

Loadshifting machinery under Hong Kong practice means plant used to raise, lower, shift or transport loads - cranes, excavators, loaders, forklifts, hoists and similar - and operators must hold the certificate/competence recognised for that plant type before operating.

A 'competent person' is a person with the relevant practical and theoretical knowledge and experience; a 'signed report' for lifting appliances and lifting gear may only be issued by an examiner appointed under the Lifting Appliances and Pressure Vessels Ordinance (Cap. 51).

Statutory examination intervals: lifting appliances and lifting gear are examined at least once every 12 months; after substantial repair, alteration, or after any accident likely to affect safety, a further examination is required before use resumes.

The rated capacity (SWL) applies only to the configuration stated on the load chart - capacity falls as radius increases and as boom/jib length increases; the operator must read the chart for the actual radius, not the maximum figure.

Radius is measured horizontally from the slewing centre (or the point stated in the chart) to the vertical hoist line - not to the hook block edge or the boom tip.

Sling angle rule: the load in each leg rises as the leg angle from horizontal decreases; for a two-leg sling of equal legs, leg tension = (load/2) ÷ sin(angle from horizontal). At 30° from horizontal each leg carries the full load.

Never exceed the manufacturer's rated capacity; use the load chart, a load indicator or a load cell to confirm the load, and reduce capacity for wind, dynamic effects, side loading and out-of-level ground as instructed by the manufacturer.

Pre-use checks before every shift: tyres/tracks and pressures, brakes, steering, hydraulic hoses and cylinders for leaks, wire ropes for broken wires or kinks, hooks for cracks and missing safety latches, limit switches, alarms, lights and the load chart in the cab.

Outriggers must be fully extended and set on solid bearing (mats or spreader plates) with the machine level; the wheels/tyres clear of the ground where the manufacturer requires it, and the outrigger beam locked.

Exclusion zone rule: no person stands under a suspended load or within the slew radius; the operator keeps the load in view or works under a signaller whose signals are agreed and, where practicable, radio or hand-signal coded.

Ground conditions govern stability: check for voids, backfilled trenches, drains, slopes and services before setting up; the bearing pressure under each outrigger or wheel must be within the ground's capacity.

Travel with a load: keep the load low, boom or forks retracted/tilted back, and speed low; never travel with a raised load beyond the manufacturer's permitted configuration, and never carry passengers.

Parking and shutdown: land the load, lower the attachment to the ground, apply the parking brake, neutralise controls, remove the key and isolate the battery where required; chock on slopes.

When a load must be left suspended, only under a documented safe system of work with the area barricaded and continuous supervision; the preferred rule is that no load is left suspended unattended.

Emergency response: stop the operation, lower the load safely if possible, isolate power, report to the supervisor and record the incident; do not return the machine to service after a shock load or structural contact until it has been inspected by a competent person.

Standard hand signals to know: raise/lower (arm and forearm up/down), stop (arm held out, palm down, held), emergency stop (both arms raised), slew left/right (arm extended pointing in the direction of travel), and travel/hoist signals - all given by one designated signaller only.

One signaller, one channel: where radio is used, agree the channel and call signs, repeat back the instruction, and stop the operation if communication is lost; the operator obeys the emergency stop signal from anyone.

Hook and sling inspection before use: check the safety latch closes, hook throat opening has not spread, no cracks or weld repairs, and the SWL or identification tag is legible.

Sling selection: wire rope slings for abrasive and hot-free loads, chain slings for abrasion and heat, webbing for delicate loads; never use a sling with a cut, knot, broken wire cluster or illegible tag.

Sharp-edge protection and corner load control: use packing or edge protectors, keep the load balanced, and use tag lines to control rotation rather than standing under the load.

Colour coding and tag systems used on site (for example periodic inspection tags) indicate inspection status, not capacity - always confirm the marked SWL against the load chart.

Reject and quarantine any lifting gear that has been overloaded, shock-loaded or damaged; tag it out of service and report it, rather than returning it to the rack.

Factories and Industrial Undertakings (Lifting Appliances and Lifting Gear) Regulations (Cap. 59 sub-legislation) require lifting appliances and lifting gear to be of good construction, sound material, adequate strength and free from patent defect, and to be examined and certified as required.

Only a trained, certificated operator may operate loadshifting machinery; the operator is responsible for the machine's safe condition during the shift and must report defects to the employer rather than operate a defective machine.

The Construction Sites (Safety) Regulations (Cap. 59A) place duties on contractors and operators regarding safe plant, guarding of machinery, and the prevention of falls and falling objects.

The Occupational Safety and Health Ordinance (Cap. 509) imposes a general duty on employers and employees to ensure safety at work; an employee must take reasonable care and cooperate with safety measures.

A lift plan / risk assessment is required before complex lifts (tandem lifts, lifts near power lines, lifts over live areas, or lifts at or near rated capacity); the plan identifies the load weight, radius, ground bearing and exclusion zone.

Near overhead power lines: observe the clearance distances required by the electricity supplier/statutory code, treat lines as live, and use a banksman; if contact occurs, keep clear and call the supply authority.

Records: examination certificates, operator certificates, maintenance and pre-use check sheets must be kept available for inspection; the operator should confirm the certificate is current before taking over the machine.

Load weight = volume × density. Common densities (approx.): steel 7,850 kg/m³, concrete 2,400 kg/m³, water 1,000 kg/m³, timber 600–900 kg/m³ - estimate each item, then add slings, spreader beam and hook block.

Total load on the crane = payload + lifting gear + any attached device; compare this total, not the payload alone, against the rated capacity at the working radius.

Two-leg sling at angle θ from horizontal, equal legs: tension per leg T = W ÷ (2 sin θ). Four-leg sling: assume only two legs share the load unless the geometry and rigidity guarantee otherwise.

Sling angle factors (relative to a vertical single leg): at 90° from horizontal ×1.0, at 60° ×1.155, at 45° ×1.414, at 30° ×2.0 - multiply the share of the load by the factor to get leg tension.

Centre of gravity: the hook must be directly above the centre of gravity or the load will tilt; for an off-centre lift, calculate the moment about the pick points to find each sling's share of the load.

Bearing pressure under an outrigger pad ≈ outrigger load ÷ pad contact area; increase pad area with mats to bring pressure within the ground's allowable bearing capacity.

Working radius and capacity check sequence: measure radius, read the chart for the boom length and configuration, deduct the lifting gear, then confirm the remaining capacity exceeds the payload with a margin for wind and dynamics.

Crawler cranes: stable on soft ground because of low bearing pressure but require level, well-drained standing; capacity charts are usually for a specific track configuration and counterweight.

Mobile/truck cranes: travel on tyres, lift on outriggers; the 'on-tyres' chart is much lower than the 'on-outriggers' chart - never use the outrigger chart for a pick-and-carry.

Tower cranes: capacity falls with jib radius; the load moment limiter and the trolley position determine the permitted load, and the operator must not rely on the hoist limit alone.

Excavators and loaders: the rated load depends on bucket/attachment, reach and counterweight; keep the machine level, dig with the dipper not the bucket side, and never swing over people.

Forklifts: rated capacity is stated at a given load centre (commonly 500–600 mm); moving the load centre forward or fitting an attachment reduces the safe capacity - check the data plate.

Hoists and gin wheels: check the SWL of the hoist, rope, pulley and anchorage, and ensure the gin wheel is properly secured and the load is guided, not swung.

Attachments (grabs, magnets, spreader beams, man-riding baskets) change the load case and require the manufacturer's/competent person's approval and a revised capacity calculation before use.

Daily pre-use inspection is the operator's duty; statutory thorough examination by an appointed examiner is a separate requirement and does not replace the daily check.

Wire rope discard criteria include broken wires in a given length, reduction in diameter, corrosion, kinking, crushing, and end-fitting damage - follow the manufacturer's/standard discard table, not judgement alone.

Hydraulic systems: check oil level and look for leaks, cracked hoses and damaged seals; never search for a hydraulic leak with the hand - use cardboard or a gauge, as injected fluid causes severe injury.

Brakes, clutches, limit switches and alarms must be function-tested at the start of shift; any failure means the machine is taken out of service and tagged.

Defect reporting: record the defect, tag the machine 'out of service', inform the supervisor, and do not operate until the repair is completed and, where required, re-examined and certified.

After any overload, shock load, collision or structural contact, the appliance must be examined by a competent person before it is returned to use, and the event recorded.

Keep the machine clean and the cab free of loose items; check fire extinguisher, mirrors, reversing alarm and lights, and ensure the load chart and operating manual are in the cab.