1. Introduction

Excavators are versatile machines on construction sites, often used for lifting tasks in addition to their primary function of digging and earthmoving. However, excavators are fundamentally designed for digging, not as dedicated lifting cranes. This inherent difference introduces specific risks when using them for lifting. This guide aims to provide comprehensive guidance on lifting operations in construction when using excavators, helping construction professionals safely and effectively use these machines for lifting while understanding the potential hazards. These risks include overloading, tipping, and load drops, which can lead to severe accidents. This guide aims to provide detailed instructions to help construction professionals safely and effectively use excavators for lifting while understanding the potential hazards.

2. Planning and Risk Assessment

• Detailed Lift Plan: A written lift plan, prepared by a competent person, is essential before any lifting operation. This plan should encompass:
  • Load Weight and Dimensions: Accurately measure and record the load’s weight and dimensions to ensure it doesn’t exceed the excavator’s lifting capacity. Use calibrated weighing equipment for precise measurements and consider the load’s center of gravity.
  • Lift Radius and Boom Angle: The lift radius (horizontal distance from the excavator’s center of rotation to the load’s center) and boom angle significantly affect lifting capacity. Consult the excavator manufacturer’s load charts to determine safe operating parameters for the specific conditions.
  • Ground Conditions and Excavator Stability: Ensure the excavator is positioned on firm, level ground. Avoid operating on soft, sloping, or unstable surfaces. Take necessary precautions, such as using outriggers/stabilizers (if equipped) and ground mats/cribbing to distribute the load.
  • Lifting Accessories: Specify the type, size, and certification details of all lifting accessories (slings, shackles, hooks, etc.). Ensure they are compatible with the load and the excavator and are in good condition.
  • Communication between Operator and Signaler: Establish clear communication protocols, including standardized hand signals or two-way radios, especially when the operator’s view is obstructed. Ensure both the operator and signaler understand the signals and their respective roles.
  • Emergency Procedures: Develop contingency plans for various emergencies, such as load drops, equipment malfunctions, or personnel injuries. These plans should include emergency contact information, evacuation routes, and first-aid procedures.
• Risk Assessment: Conduct a thorough risk assessment to identify potential hazards and implement appropriate control measures. This assessment should cover:
  • Overloading: Ensure the load’s weight never exceeds the excavator’s rated lifting capacity at the given radius and boom angle.
  • Tipping: Evaluate ground conditions, excavator stability, lift radius, and load swing to prevent tipping.
  • Load Falling: Inspect lifting accessories for damage and ensure secure connections.
  • Collisions: Assess the lifting area for obstructions and implement measures to prevent collisions between the load, the excavator, and surrounding structures or personnel.
  • Environmental Factors: Consider weather conditions (high winds, rain, snow), visibility, and other environmental factors that may affect the lifting operation.

3. Excavator Suitability and Preparation

• Manufacturer’s Specifications: Strictly adhere to the excavator manufacturer’s operating manual and load charts. Never exceed the stated lifting limits.
• Machine Condition Check: Before each lifting operation, a competent person should thoroughly inspect the excavator, including:
  • Hydraulic System: Check hydraulic fluid levels, hoses, connections, cylinders, and pumps for leaks, damage, or wear.
  • Boom and Dipper Arm: Inspect for cracks, deformations, corrosion, or other damage.
  • Slew Ring and Bearings: Check for looseness, wear, or damage.
  • Brakes and Stabilizers: Ensure brakes and stabilizers (if fitted) are functioning correctly.
• Ground Conditions: The ground must be firm, level, and stable enough to support the excavator’s weight and the lifted load. If conditions are inadequate:
  • Use Ground Mats/Cribbing: Use appropriately sized and rated mats or cribbing to distribute the excavator’s weight and prevent sinking.
  • Use Stabilizers/Outriggers: If the excavator is equipped with them, deploy them according to the manufacturer’s instructions.
  • Avoid Slopes: Minimize operation on slopes. If unavoidable, take extra precautions and consult with a geotechnical engineer if needed.

4. Lifting Accessories

• Use Certified Lifting Gear: Only use certified lifting accessories that meet relevant standards (e.g., ASME B30.9 for slings, ASME B30.10 for hooks). Ensure all accessories are clearly marked with their Safe Working Load (SWL) or Working Load Limit (WLL).
• Correct Selection: Choose the appropriate type and size of lifting gear based on the load’s weight, shape, dimensions, and lifting points.
  • Slings: Select the correct sling type (wire rope, synthetic fiber, chain) and configuration (single leg, multi-leg) for the specific lift.
  • Shackles: Use shackles with a WLL equal to or greater than the load. Ensure proper pin engagement.
  • Hooks: Use hooks with safety latches to prevent accidental disengagement of the load.
• Regular Inspections: Inspect all lifting accessories before each use and at regular intervals (e.g., daily, weekly, monthly, depending on usage). Remove any damaged or defective equipment from service immediately.
• Avoid Makeshift Lifting Arrangements: Never use makeshift lifting arrangements like ropes, chains not designed for lifting, or other improvised methods.

5. Operating Procedures

• Competent Operator: Only trained and certified operators should perform lifting operations with excavators.
• Smooth and Controlled Movements: Lift, move, and lower loads smoothly and avoid sudden movements, jerks, or rapid acceleration/deceleration, which can cause load swing or instability.
• Keep the Load Close to the Machine: Minimize the lift radius to maximize lifting capacity and stability.
• Avoid Swinging Loads: Use tag lines to control load swing, especially in windy conditions.
• No Personnel Under the Load: Absolutely no personnel should be allowed to stand or walk under a suspended load. Establish a clear exclusion zone around the lifting area.
• Clear Communication: Use established hand signals or radio communication between the operator and signaler.
• Weather Conditions: Avoid lifting operations in high winds, heavy rain, snow, or other adverse weather conditions that could affect stability or visibility.

6. Specific Considerations for Excavators

• Not Designed for Repetitive Lifting: Excavators are designed primarily for digging and earthmoving. Frequent lifting can put excessive stress on components, shortening their lifespan and increasing the risk of failure.
• Side Lifting is Extremely Dangerous: Never lift loads from the side of the excavator. This significantly reduces stability and greatly increases the risk of tipping.
• Do Not Use Bucket Teeth for Lifting: Bucket teeth are not designed for lifting and can break or cause the load to slip. Use appropriate lifting attachments.
• Use Dedicated Lifting Attachments: Consider using dedicated lifting hooks, quick couplers, or other specialized attachments designed for lifting. These attachments often feature safety latches, swivel capabilities, and other features that enhance safety and efficiency.

7. Legal and Regulatory Requirements

Comply with all applicable local, regional, and national regulations regarding lifting operations, equipment safety, and operator certification. Consult relevant standards and guidelines.

8. Conclusion

Using excavators for lifting operations is a high-risk activity that requires careful planning, thorough risk assessment, and strict adherence to safe operating procedures. By following the guidelines outlined in this document, you can significantly reduce the risk of accidents and ensure the safety of personnel and equipment. If a lift is complex, beyond the excavator’s capabilities, or involves critical loads, using a dedicated crane is always the safest option. Safety should always be the top priority.

If you have buy used excavator or used mini excavator, you can consult us.

Please follow and like us: