Safe and Proper Aircraft Lifting Techniques

[MikePhua]

Lifting a heavy object, especially an airplane, requires a great deal of precision, proper planning, and awareness of the equipment involved. The consequences of improper lifting can lead to catastrophic damage to both the equipment and the surroundings, as well as costly repairs and delays. In the aviation and heavy equipment industries, learning how to safely lift large and expensive machinery is paramount. This article delves into the crucial aspects of lifting aircraft, the most common mistakes, and best practices to avoid disastrous outcomes.
Understanding Aircraft Weight and Structure
Before attempting to lift an airplane, it’s crucial to understand its weight, structure, and lifting points. Aircraft, especially commercial or military planes, are designed with specific lifting points to ensure that the weight is distributed evenly during transport or storage. These points are typically reinforced areas of the aircraft frame where lifting slings or hooks can be securely attached.
Each type of aircraft has its own design and specific guidelines on how to safely lift and transport it. These guidelines include identifying the center of gravity, understanding the total weight distribution, and ensuring that the lifting equipment is capable of handling the load without risking failure. When lifting smaller planes or even jet engines, there are still clear guidelines on where and how to lift them safely.
The Risks of Improper Lifting Techniques
When lifting aircraft improperly, the risks are not limited to just the equipment. Improper lifting can cause severe damage to the airplane's fuselage, wings, or landing gear, resulting in irreparable damage. The most common mistakes include using incorrect lifting points, failing to properly secure lifting equipment, and overloading the lifting gear.
Aircraft are complex structures with many delicate systems, including fuel lines, electrical wiring, and hydraulic systems. Misalignment during the lifting process can cause internal damage to these components. For instance, a slight miscalculation of the weight distribution could lead to a wing or fuselage cracking, or in extreme cases, structural failure during the lift.
Additionally, improper lifting can result in injury to personnel involved. Mishandling equipment, incorrect positioning of lifting equipment, and failure to communicate clearly can put the safety of the crew at risk. Even with proper equipment, human error in the lifting process is a leading cause of accidents in aviation maintenance and handling.
Types of Lifting Equipment Used in Aircraft Handling
Various types of lifting equipment are used when moving or lifting aircraft, depending on the size, weight, and type of aircraft being handled. Below are some of the most common equipment types used in the industry:

1. Aircraft Dollies: These are wheeled devices designed to move planes on the ground. They are most commonly used in hangars or when transporting small aircraft from one place to another within a facility. These dollies are equipped with adjustable lifting arms to accommodate various types of aircraft.
   
2. Hydraulic Aircraft Lifts: For larger aircraft, hydraulic lifts are commonly used to raise the plane off the ground. Hydraulic lifts are powered by hydraulic fluid and can handle significant weight. The lifting force is controlled by the operator and can be adjusted to lift the plane evenly.
   
3. Cranes: Cranes are essential for lifting and moving larger planes, especially when they need to be hoisted into storage or during maintenance. When using a crane, lifting slings and hooks are attached to the plane's designated lifting points.
   
4. Jack Systems: Some aircraft require the use of a jack system, especially for smaller aircraft or individual components like engines or landing gear. Jacks are often used when the aircraft needs to be lifted for servicing or maintenance.
   

Best Practices for Lifting Aircraft Safely

1. Use Approved Lifting Points: Aircraft manufacturers provide clear guidance on where the lifting points are located. These points are designed to distribute the load evenly across the aircraft’s structure. Using non-designated areas could cause undue stress and result in structural damage.
   
2. Inspect Lifting Equipment: Before attempting any lift, it’s crucial to inspect all lifting equipment, including cranes, jacks, and slings. Look for signs of wear or damage, and ensure that the equipment can handle the weight of the aircraft. Failing to check the equipment can lead to catastrophic failure during the lift.
   
3. Calculate the Weight Distribution: Every aircraft has a unique weight distribution. For example, the fuselage, wings, and tail all contribute to the overall weight. Understanding the distribution helps ensure that the load is evenly lifted, reducing the chance of tipping or straining the structure. This can also help in setting up the lifting equipment for proper weight support.
   
4. Avoid Overloading the Equipment: Ensure that the lifting gear is rated for the aircraft’s weight, and never attempt to lift an aircraft with equipment that doesn’t meet the required specifications. Overloading the equipment is one of the most common mistakes in lifting heavy machinery and can lead to failure.
   
5. Have a Qualified Team: Lifting an aircraft is not a one-person job. It requires a skilled team of individuals who understand the complexities involved. Each member of the team should be trained in lifting techniques, understand the aircraft’s structure, and be aware of potential hazards.
   
6. Clear Communication: Effective communication is critical when lifting any heavy equipment. A lift should never begin until all team members are fully aware of their roles, and any potential issues are addressed. Communication should be clear, with hand signals or radio communication to avoid miscommunication during the operation.
   
7. Use a Lift Plan: Before any lift takes place, a detailed lift plan should be developed, which includes all the steps for lifting, moving, and securing the aircraft. The plan should account for any obstacles, weather conditions, or other variables that could affect the operation. This proactive approach can help prevent accidents or mishaps during the lifting process.
   

Common Mistakes in Aircraft Lifting

1. Using the Wrong Lifting Points: One of the most common and costly mistakes is using incorrect lifting points. Aircraft are designed to be lifted at specific points to avoid damaging sensitive components. Failure to follow these guidelines can lead to permanent damage.
   
2. Improper Equipment Setup: A common error is setting up lifting equipment improperly. This includes incorrect attachment of lifting slings, failing to verify the weight capacity of cranes or jacks, and improper positioning of the aircraft during the lift.
   
3. Underestimating the Weight: Overestimating the lifting capacity of the equipment or underestimating the weight of the aircraft can result in failure. Always ensure accurate weight calculations, factoring in any equipment or modifications on the aircraft.
   
4. Lack of Safety Protocols: Failure to implement proper safety protocols, such as securing the work area and wearing appropriate protective gear, can endanger personnel. Safety is paramount when lifting heavy objects, and all protocols should be strictly followed.
   

Conclusion
Lifting aircraft, whether for maintenance, transport, or storage, is an operation that requires meticulous planning and attention to detail. Understanding the risks involved and adhering to best practices can help ensure that the aircraft is safely lifted and transported without incurring unnecessary damage or risks to personnel. By using the right equipment, following manufacturer guidelines, and maintaining effective communication, the lifting process becomes a manageable and safe task. The key is preparation, knowledge, and ensuring that all involved understand the procedures to prevent costly mistakes.