Planning

Common Lift Planning Mistakes (And How to Avoid Them)

Updated May 22, 2026

10 min read

Ricky Marsh

Lifting team reviewing and marking up a lift plan on site — catching planning mistakes before the lift goes ahead

After reviewing over 1,000 lift plans across 35 years in construction, certain mistakes appear repeatedly. This guide examines the most common lift planning errors and how to avoid them.

A printed lift plan on a site office desk marked up with red-pen corrections and circled notes, beside reading glasses and a hard hat — the kind of errors caught during an independent lift plan review — Most lift planning mistakes are avoidable — and the cheapest place to catch them is at the desk, before the plan ever reaches site.

Overview graphic listing the eight most common lift planning mistakes: underestimating load weights, inadequate ground assessment, missing overhead hazards, inadequate communication planning, no plan for changing conditions, ignoring manufacturer load charts, poor rigging practices, and not documenting the plan — The eight mistakes that appear again and again in lift plans — each one covered in detail below.

Mistake 1: Underestimating Load Weights

The most fundamental error is not knowing what you're actually lifting. A 900mm diameter concrete pipe 3 meters long weighs approximately 2.5 tonnes—what appears manageable can quickly exceed equipment capacity.

How to Avoid It

Always verify weights from manufacturer data sheets
Include weight of all lifting accessories
Apply realistic contingency (typically 10-15%)
Document weight sources with the lift plan

Mistake 2: Inadequate Ground Assessment

Ground conditions beneath lifting equipment are critical to stability, yet proper assessment is frequently overlooked. Visual assessment alone is insufficient.

How to Avoid It

Identify soil type and condition properly
Calculate actual bearing pressures
Use ground mats sized appropriately
Maintain safe distances from excavations

Mistake 3: Failing to Identify Overhead Hazards

Overhead power lines and structures create exclusion zones. Failure to identify these has caused numerous fatalities in UK construction.

How to Avoid It

Walk the entire site looking specifically for overhead lines
Apply HSE Guidance Note GS6 clearance distances
Implement physical exclusion zone barriers
Consider line diversion for major projects

Mistake 4: Inadequate Communication Planning

Even perfectly planned lifts fail without effective communication between all involved parties.

How to Avoid It

Brief all personnel before every complex lift
Designate one person to communicate with operator
Use standardized BS 7121 hand signals
Test communications before lifting begins

Mistake 5: No Plan for Changing Conditions

Lift plans based on ideal conditions often fail to account for reality. Specify maximum wind speeds, define decision points, and build flexibility into plans.

Mistake 6: Ignoring Manufacturer Instructions

Equipment manufacturers provide load charts for good reason, yet these are frequently ignored. Always consult manufacturer data and stay within specified limits.

Mistake 7: Poor Rigging Practices

How loads are attached to lifting equipment is critical. Plan rigging in detail, understand sling angle effects, and inspect all rigging before use.

Mistake 8: Not Documenting the Plan

Even when operations are properly planned, failing to document creates compliance and safety issues. Document all non-routine lifts in writing.

Conclusion: Learning from Mistakes

Every mistake discussed here has caused real accidents, delays, and regulatory action in UK construction. The good news is every one is avoidable through proper training, careful planning, and adherence to best practices.

Key themes: Competence matters. Documentation is essential. Details matter. For contractors serious about lifting safety, learning from others' mistakes is far less painful than repeating them.

Avoid These Mistakes

RMT Solutions provides LOLER-compliant lift planning from a CPCS Appointed Person with 35 years of experience. We offer professional lift plan writing and independent lift plan checking to ensure your operations are safe and compliant.

Ricky Marsh

CPCS Appointed Person (A61, Reg: 40389279) | NEBOSH National Diploma | CertIOSH | MIIRSM | TIFSM

With 35 years of construction industry experience, Ricky provides expert lift planning and compliance services to contractors across the UK. Specializing in LOLER compliant lift plans, tower crane contracts, and steel erection planning.