Lifting heavy parts to the correct working height seems simple, but in practice, things often go wrong: a part that’s too low, an employee who has to bend over uncomfortably, or a load that isn’t positioned stably. The result is not only inefficient but also dangerous. With the right approach and the right lifting aid, you can lift heavy loads safely, ergonomically, and precisely to the desired working height.
In this guide, you’ll go through five specific steps: from determining the characteristics of your load to properly maintaining your lifting equipment. Whether you’re working with metal sheets, heavy machine parts, or bulk goods, these steps will help you organize the process safely and efficiently.
Determine the weight and shape of the part
Before you lift anything, assess the characteristics of the item. This is the foundation of every safe lifting operation. Anyone who skips this step risks choosing the wrong lifting device or exceeding the maximum load capacity.
- Weigh the part or refer to the technical specifications. Record the exact weight in kilograms.
- Determine the shape: Is the part flat, cylindrical, irregular, or fragile? This will determine which gripping mechanism is appropriate.
- Check the surface: Is it smooth, porous, greasy, or perforated? This will determine whether to use a vacuum lifter, clamp, or hook.
- Record the dimensions (length, width, height) and the center of gravity. An elongated component with an eccentric center of gravity requires a different approach than a compact, symmetrical load.
After this step, you will have a clear profile of your load. Check whether the weight and dimensions fall within the specifications of the lifting device you are considering using. If they do not, stop here and find a more suitable alternative.
Choose the right lifting aid for your situation
Once you’ve assessed the characteristics of the component, choose the lifting aid that best suits your specific situation. There is no one-size-fits-all solution: the choice depends on weight, shape, workspace, and frequency of use.
- Vacuum lifters and hoists: ideal for smooth, flat materials such as sheets, glass, or metal plates. They grip the surface using suction cups and allow for precise positioning. Explore the options for vacuum lifters and hoists.
- Mobile lifts: suitable for heavy, compact parts that need to be positioned at a specific working height. A mobile lift offers great flexibility in height adjustment and can be moved freely within the workspace.
- Pallet trucks (electric or manual): for moving and positioning pallets or large items on pallets.
- Pulling aids: for moving heavy loads horizontally across floors or rails, when height adjustment is less important.
When making your choice, also consider the workspace. A narrow hallway or a room with a low ceiling limits your options. Also check whether the floor can support the combined weight of the lifting device and the load. If you’re unsure which lifting device is most suitable, review the list of applications to see what solutions are available for your type of load.
Set the correct working height before lifting
A common mistake is to lift the component first and then try to adjust the working height. Do it the other way around: set the desired working height before you start lifting. That’s both safer and more efficient.
- Determine the ideal working height for the task. As a rule of thumb, this is the height at which your elbows are slightly bent and your shoulders remain relaxed. For most people, this is between 90 and 110 centimeters above the floor, depending on the task.
- Set the lifting height of your lifting device to the desired final position. For a mobile lift, do this using the height adjuster before picking up the load.
- Check whether the setting is locked or stable before lifting the load.
- Never adjust the height while the load is already suspended in the air, unless the lifting device is specifically designed for that purpose and the load is securely fastened.
After adjusting the working height, check to make sure there is enough space to place the part at the target location. Be aware of any obstacles above or next to the work area. Proper preparation here will save you from having to make corrective movements later, which often pose the greatest risks when it comes to ergonomic lifting.
Position the part safely and accurately
With the working height set correctly and the part secured in the lifting device, move the load to the target location. Precise positioning requires controlled movements and a proper work setup.
- Move the lifting device slowly and in a straight line toward the target location. Avoid sudden changes in direction while the load is in the air.
- Make sure the target location is clear of obstacles before lowering the load. Visually check this before you begin lowering it.
- Lower the load slowly and carefully to the desired position. Use the fine-tuning control on your tool, if available.
- Make sure the component is stable and properly positioned before disconnecting it from the lifting device.
Precision is crucial when positioning heavy loads on machines or in assemblies. Some lifting aids offer rotation or tilting capabilities that allow you to position the part at exactly the right angle. Use these features instead of manually adjusting the load, as that significantly increases the risk of injury. For specific applications such as sheet metal handling or roll handling, there are specialized tools that further simplify positioning.
Maintain Your Lifting Aid for Ongoing Safety
A lifting device that isn't properly maintained is a safety hazard. Wear and tear, leaking hydraulics, or faulty locks can lead to unexpected failures when you least expect them. Regular maintenance isn't an option—it's a requirement.
- Perform a daily visual inspection before use: check for visible damage, leaks, loose parts, or unusual noises.
- Lubricate moving parts regularly according to the manufacturer's recommendations.
- Check the load capacity and ensure that the maximum lifting capacity remains clearly visible on the equipment.
- Schedule periodic professional inspections, especially if the equipment is used intensively. This includes checking hydraulic systems, electrical components, and safety interlock systems.
- Record all maintenance visits and any defects in a logbook.
If a lifting device is defective, take it out of service until it has been repaired. Never use a damaged or uncertified device. A well-maintained device retains its lifting capacity, accuracy, and safety over the long term. For more information about service solutions, visit the service page.
How Logitrans Handling Helps Ensure the Safe Positioning of Heavy Parts
We understand that every workplace and every load is different. That’s why we don’t offer one-size-fits-all solutions, but rather a customized approach tailored to your specific situation. Specifically, we offer:
- Free workstation analysis: Our specialists will analyze your workstation and lifting situation on-site and recommend the most ergonomic and efficient solution.
- Extensive product range: from mobile lifters and vacuum lifters to pallet trucks and pulling aids, tailored to weight, shape, and work environment.
- Demonstration Room in Drongen: Test the lifting aid with your own materials before making a decision, so you can be sure the system works for your situation.
- Maintenance Contracts: We ensure that your lifting equipment remains in optimal condition—through both preventive and corrective maintenance—so that safety in the workplace is guaranteed.
- User Training: Upon delivery or installation, we will train your employees so they can use the device correctly and safely.
Would you like to know which lifting aid is best suited to your situation? Feel free to contact us for a no-obligation consultation or a free workstation analysis.
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