SWMS template · Crane, Lifting & Rigging
Chain Block and Manual Hoisting — Safe Work Method Statement
Safe Work Method Statement for lifting and positioning loads with chain blocks, lever hoists, beam trolleys, gin wheels and hand winches, covering load weights, anchor point capacity, pre-use inspection, rigging and hoisting materials to a scaffold or upper level.
- Category
- Crane, Lifting & Rigging
- HRCW
- 1 category
- Job steps
- 7
- Hazards rated
- 17
- PPE items
- 6
Chain blocks (manual chain hoists), lever hoists, beam trolleys, gin wheels and hand winches are used by mechanical fitters, plumbers, plant installers, electricians and builders to lift pumps, motors, valves, pipe, plant and materials where a crane will not fit or is not worth bringing in. Because there is no engine and no licence card, this work is often treated casually, but the load is just as heavy and the anchor point is often the weakest link on the job.
Manual hoisting is not High Risk Construction Work in itself. It becomes HRCW when a person is at risk of falling more than 2 metres, for example hauling materials up to a scaffold with a gin wheel or lifting from a mezzanine or roof edge, and that is the case this template is written for. If all the work is at ground level and no other HRCW applies, a SWMS is not legally required, but it is still good practice and principal contractors often require one.
The critical decision is the anchor point. Chain blocks get hung from pipes, cable trays, purlins, roof trusses, scaffold tubes and steel beams that were never designed for a point load, and the hook load includes the load, the block and any shock from jerking or a slipped chain. Use a designed lifting beam or lug with a marked working load limit, or have an engineer confirm the structure can take the load. Other specific hazards are overloading the block, loads sliding off the hook tip, twisted chains, side pulling, extending a lever hoist handle with a pipe, gin wheel ropes failing, loads falling on people below, and workers being pulled off the edge or straining their backs hand-hauling.
No high risk work licence is needed to operate a chain block. If the job involves slinging loads in a way that needs judgement about sling selection and load behaviour, or rigging lifting gear to structure, a dogging or rigging licence may be required. Check your state or territory regulator. Lifting equipment must be inspected by a competent person at the interval the manufacturer or site sets (many sites use a 3-monthly colour tag system), and checked by the user before every lift.
Customise this template with the loads and their weights, the chain blocks, lever hoists or gin wheels in use and their working load limits, each anchor point and how its capacity was confirmed, the slings and shackles, the edge protection or fall restraint at upper levels, the exclusion zone below the hoisting area, and the inspection tag colour for the current period.
Important: This SWMS template is a starting point only. Review and customise it for your workplace and task. The PCBU remains responsible for ensuring the SWMS is suitable for the work. Not legal advice.
High Risk Construction Work Types
- Risk of a person falling more than 2 metres
Personal Protective Equipment
- Hard hat with chin strap (for work below hoisting areas)
- Rigger's gloves
- Steel-capped safety boots
- Safety glasses
- Full-body harness and restraint lanyard (AS/NZS 1891) where edge protection is removed for hoisting
- High-visibility vest
Risk Assessment
RatingsCatastrophicHighModerateLow
Step 1Confirm the load weight and select the equipment
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Chain block, lever hoist or gin wheel overloaded | High | Get the load weight from the nameplate, manufacturer data or a calculation. Add the weight of slings, shackles and spreaders. Select a hoist and gear with a working load limit above the total. If the weight is unknown, do not lift until it is confirmed. | Low | Supervisor / Fitter |
| Wrong device for the job, such as a lever hoist used for long vertical lifts or a gin wheel for heavy items | Moderate | Use chain blocks for vertical lifting, lever hoists for short pulls, tensioning and positioning, and gin wheels only for light materials within the wheel's marked rating and what a person can safely haul. Use a crane or powered hoist for anything beyond that. | Low | Supervisor |
Step 2Select and confirm the anchor point
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Anchor point or structure fails under the load | Catastrophic | Hang hoists only from a designed lifting beam, lug or monorail with a marked working load limit, or from a structural member an engineer has confirmed can carry the load plus allowance for shock. Never use pipes, cable trays, purlins, ceiling framing, roof trusses or scaffold tubes unless they have been specifically designed or assessed for it. | Low | Supervisor / Engineer |
| Beam clamp slips off the flange | High | Use a beam clamp sized to the flange width and thickness, tightened as the manufacturer specifies, with a working load limit above the load. Check the clamp is square and fully seated before lifting. | Low | Fitter / Rigger |
Step 3Pre-use inspection
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Worn or damaged hoist fails during the lift | High | Before each use, check the inspection tag is current, the hook safety latches work, hooks are not opened up or twisted, the load chain is not stretched, nicked, rusted or twisted, and the bottom block has not capsized through the chain. Test the brake with a light load before lifting. Remove faulty gear from service and tag it out. | Low | User / Competent Person |
| Gin wheel rope or fixing fails | High | Check the rope for cuts, fraying, burns and chemical damage, and the wheel for wear and a working safety catch. Fix the gin wheel only to a scaffold or structure designed for it, using the fixing method the scaffolder or manufacturer specifies. | Low | User / Scaffolder |
Step 4Rigging and lifting the load
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Load slips off the hook tip or the hook is side loaded | High | Seat the sling or shackle in the bowl of the hook with the latch closed. Keep the hoist directly above the load and pull vertically. Do not drag loads sideways with the hoist. | Low | Fitter / Rigger |
| Load falls on a person below | Catastrophic | Barricade the area under and around the lift. Nobody under a suspended load at any time. Lift a short distance, stop and check the brake holds and the load is balanced before continuing. | Low | All Workers |
| Lever hoist overloaded with an extended handle | High | Never extend the lever handle with a pipe or bar. If the hoist will not pull with normal hand force, stop, the load is too heavy or snagged. | Low | User |
| Strain injury from long hauls on the hand chain | Moderate | Stand on firm footing in line with the hand chain. Rotate workers on long lifts. Use a powered hoist for frequent or high lifts. | Low | Supervisor / User |
Step 5Moving loads with a beam trolley
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Trolley runs off the end of the beam | High | Confirm end stops are fitted to both ends of the beam before use. Set trolley width to the flange as the manufacturer specifies. | Low | Fitter / Rigger |
| Load swings into workers or structure | Moderate | Push the load rather than pulling it toward you. Move slowly with the load just clear of obstacles. Use a tag line where you cannot stay clear of the swing. | Low | User |
Step 6Hoisting materials to a scaffold or upper level with a gin wheel
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Worker falls from the upper level while receiving loads | Catastrophic | Receive loads only at a loading point with edge protection and a self-closing gate, or with the worker in a restraint system that stops them reaching the edge. Never lean out to grab a load. | Low | Supervisor / Workers |
| Materials fall from the gin wheel onto people below | High | Barricade an exclusion zone below the hoisting point. Secure loads in a bucket or bag with a closed hook, or tie them with a hitch that will not slip. Keep the hauling worker out from under the load. | Low | Supervisor / Workers |
| Back strain from hand-hauling | Moderate | Keep individual loads light and within the wheel's rating. Haul hand over hand without jerking. Rotate workers and use a powered hoist for large quantities. | Low | Supervisor |
Step 7Lowering, de-rigging and storage
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Load drops or tips when lowered | Moderate | Lower slowly onto level bearers. Confirm the load is stable before slackening the chain or removing slings. | Low | Fitter / Rigger |
| Damaged equipment returned to service | Moderate | Inspect gear after use. Tag out and report damage. Store chain blocks and slings clean, dry and hung up off the ground. | Low | User |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.
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