How to Write a Critical Lift Plan: Template, Required Sections & Approval Process

What Is a Critical Lift?

Not every crane lift requires a formal critical lift plan — but identifying which lifts do is itself a critical competency. Across the major standards and regulatory frameworks, a lift is classified as "critical" when it meets one or more of the following thresholds:

ASME B30.5 / ASME P30.1 (US and widely adopted internationally):

• Load exceeds 75% of the crane's rated capacity at the working radius
• Multiple crane lift (two or more cranes working together)
• The lift involves hazardous materials
• The load path passes over occupied areas
• Unusual or non-routine loads (complex geometry, uncertain centre of gravity)
• Lifts near power lines or in confined airspace

LOLER 1998 / BS 7121 (UK and jurisdictions following UK practice, including some GCC projects):

• Any lift where a failure could cause injury or significant property damage
• All lifts by the Appointed Person standard require a risk assessment and method statement; "critical" lifts require a formal written plan signed by a competent person

DGFASAI / IS Standards (India):

• Lifts above 75% SWL
• Tandem lifts
• Any lift where the load path passes over process plant, occupied buildings, or high-value equipment

In practice: If you are unsure whether a specific lift is critical, treat it as critical. The cost of a lift plan is trivial compared to the cost of an incident.

Who Writes the Critical Lift Plan?

A critical lift plan must be prepared by a competent person — defined in most jurisdictions as a person with the knowledge, training, and experience to identify hazards and design safe lifting operations. For critical lifts, this typically means:

• A Lifting Engineer or Appointed Person (UK/LEEA terminology) — a professional with specific lifting operations education and experience
• A Rigging Engineer or Structural Engineer (EPC contractor terminology) — an engineer who has reviewed the crane load chart, rigging configuration, and ground conditions
• Not the crane operator, not the site supervisor — unless that person holds specific lifting engineering qualifications

The plan must be signed off by the engineer who prepared it and countersigned by the project lifting authority or HSE manager. For lifts above a certain threshold (typically 75% crane capacity or tandem lifts), most major oil and gas, petrochemical, and power generation project owners require independent review by a third-party lifting specialist.

The 12 Required Sections of a Critical Lift Plan

Critical Lift Plan — Required Sections

Sections 1–6

1. Lift Overview & Classification

2. Load Description & Weight

3. Centre of Gravity Analysis

4. Crane Selection & Configuration

5. Load Chart Verification

6. Ground Bearing & Outrigger Plan

Sections 7–12

7. Rigging Arrangement Drawing

8. Lift Sequence & Method Statement

9. Environmental Limits

10. Communication Plan

11. Emergency Response Plan

12. Approval Signatures

All sections required for lifts ≥75% crane SWL or multi-crane operations

Section 1: Lift Overview and Classification

This section establishes the basis for the plan and confirms that the lift meets the threshold for a critical lift plan.

Required content:

• Project name, location, and date(s) of lift
• Lift description (what is being lifted, from where, to where)
• Classification statement: which criteria make this lift critical (e.g., "Load is 82% of crane rated capacity at 18 m radius")
• Plan number, revision status, and issue date

Section 2: Load Description and Weight

A critical lift plan must document the load weight from a verifiable source — not an estimate.

Required content:

• Load description (component name, tag number, material)
• Verified weight source: manufacturing drawing, mill certificate, weigh ticket, or in-line load cell measurement
• Load dimensions (overall length, width, height)
• Any attached items included in the lift weight (slings, spreader bars, temporary attachments)
• Total gross weight = load + all below-hook devices + rigging

Section 3: Centre of Gravity Analysis

For any load that is not a simple symmetric shape, the centre of gravity (CoG) must be calculated and documented.

Required content:

• CoG coordinates (X, Y, Z from a defined datum)
• CoG determination method (calculation from drawing, direct measurement by tilting, or engineering estimate with tolerance)
• CoG marking on the load (if applicable)
• Tipping angle analysis: if the rigging attachment points are not directly above the CoG, document the equilibrium angle and confirm it is acceptable

CoG offset consequence: If the CoG is offset from the centre of the sling basket, the load hangs at an angle. A 200 mm offset on a 6 m wide load creates approximately a 1.9° tilt. For process vessels, piping connections, and structural members, this can mean the load cannot be landed in its final position without sling adjustment mid-lift — a high-risk operation that must be planned in detail.

Section 4: Crane Selection and Configuration

Document the crane that will perform the lift and its precise configuration for this lift.

Required content:

• Crane make, model, and serial number
• Configuration: boom length, boom angle, jib attachment (if applicable), counterweight mass
• Outrigger status: full or partial outrigger extension
• Free-on-wheels vs outrigger operation
• Confirmation that the crane's load test certificate is current

Section 5: Load Chart Verification

This is the engineering heart of the critical lift plan. The load chart must be read for the exact configuration stated in Section 4 at the exact radius of the lift.

Required content:

• Operating radius (measured from crane centre pin to load CoG, not to load edge)
• Crane capacity at this radius and configuration (from the manufacturer's load chart, not an approximation)
• Percentage of capacity utilised: (Gross Load ÷ Chart Capacity) × 100%
• Confirmation that utilisation does not exceed the project's maximum (typically 85–90% for critical lifts; some projects cap at 75%)

Important: Deduct the weight of the hook block, headache ball, shackles, and all below-hook devices from the chart capacity before comparing with the load weight. Charts show gross capacity from the hook, not net load.

Section 6: Ground Bearing and Outrigger Plan

For mobile cranes: calculate and document the outrigger pad pressure for the planned configuration.

Required content:

• Maximum outrigger reaction forces (obtained from the crane manufacturer's outrigger reaction tables for the planned configuration)
• Outrigger pad size selected
• Calculated ground pressure (force ÷ pad area)
• Verified ground bearing capacity at each outrigger location
• Mat type, size, and material if used
• Site drawing showing outrigger positions relative to excavations, underground services, and site boundaries

For tower cranes: include foundation design reference and the foundation engineer's certification.

Section 7: Rigging Arrangement Drawing

A dimensioned drawing showing:

• Load shape with CoG marked
• Sling attachment points with connection method (shackle size, sling type, basket vs choker)
• Sling lengths, angles from vertical, and calculated leg loads
• Spreader bar or lifting beam (if used) with identification number and capacity certificate reference
• Hook block and all below-hook hardware identified

The rigging drawing must confirm that all sling angles are within limits (generally ≤60° from vertical for synthetic slings; manufacturer's limits for chain or wire rope slings).

Section 8: Lift Sequence and Method Statement

Step-by-step description of the lift from pre-lift setup through load placement and hook release.

Must include:

• Pre-lift checks and hold points (mandatory stops for inspection/authorisation)
• Pick point setup procedure
• Initial lift and load verification sequence
• Load travel path with clearances to all obstacles documented
• Landing procedure and load securing before hook release
• Emergency hold points: conditions under which the lift will be suspended

Section 9: Environmental Limits

Specify the conditions under which the lift will not proceed:

• Maximum wind speed (in m/s or km/h) for this specific lift
• Minimum visibility
• Any restrictions on time of day (some lifts must occur during low-traffic periods; some must avoid peak temperature periods for process vessels)
• Confirmation that weather has been checked and is within limits before lift commences

Section 10: Communication Plan

• Identify the Appointed Person / Lifting Supervisor by name
• Identify the crane operator by name and confirm current authorisation
• Identify the signaller(s) by name
• Confirm communication method (radio, hand signals, or both)
• Confirm frequency/channel if radio is used
• Identify who has authority to call "STOP" — all personnel must understand that any person can call an emergency stop

Section 11: Emergency Response Plan

What happens if something goes wrong during the lift:

• Who to call (site emergency number, crane OEM emergency line, nearest hospital)
• Assembly point
• Procedure if load is stuck mid-air (securing, personnel evacuation, crane hold procedure)
• Procedure if crane LMI activates or structural creak/sound occurs during lift

Section 12: Approval Signatures

At minimum:

• Lift plan author (lifting engineer) — signature, qualification, date
• Lifting supervisor (the person managing the lift on site) — signature, date
• HSE manager — signature, date
• Project manager or client representative (for lifts above the project threshold) — signature, date

For tandem lifts and lifts above 90% SWL: require a second independent lifting engineer to countersign the load chart verification.

The Approval Process for Major EPC Projects

On major oil and gas, petrochemical, and power projects, critical lift plans typically go through a formal approval workflow:

Step 1 — Prepare: Lifting engineer prepares the plan using project-specific template. Minimum 5 working days before the planned lift date.

Step 2 — Internal Review: Construction manager and HSE manager review within 48 hours.

Step 3 — Client Review: Client lifting authority reviews and returns comments within 48 hours.

Step 4 — Closeout: All comments addressed and plan revised. Final signatures obtained.

Step 5 — Pre-Lift Toolbox Talk: 30–60 minutes before the lift, all personnel involved attend a briefing covering the plan, roles, communication, and emergency response.

Step 6 — Hold Points: The Appointed Person signs off at each hold point during execution. The plan is not just a document — it is a live operational control.

Key Takeaways