Rope and Sling Specialists Ltd. (RSS) and Sheffield Forgemasters welcomed invited lifting professionals to each of their South Yorkshire, UK facilities earlier this month (8 July) for a special event that showcased an innovative safer lifting operations project.
The discovery day was held at RSS’s Rotherham depot, but a highlight was a site visit to Sheffield Forgemasters’ new 30,000 m² machine shop, where the framework is almost complete. It was strategically scheduled the week after Global Lifting Awareness Day (GLAD), which was underscored this year by the Lifting Equipment Engineers Association’s (LEEA) 2026 tagline: ‘Not all lifting equipment is created equal’. Ross Moloney, CEO of LEEA, delivered the opening presentation. A wide-ranging paper examined three types of risk, all of which chimed with the day’s core message:
- Traceability risk: can you prove the manufacturer, batch, standard, declaration, instructions and test history?
- Suitability risk: is it actually suitable for the lift, environment, duty cycle, angle, edge exposure, temperature and configuration?
- Competence risk: who checked it, accepted it into service, examined it and recorded it?
Ross Moloney, CEO of LEEA, delivered the opening presentation.
Moloney said: “Most serious failures are not single-point failures. They are system failures. We need to move from ‘was the equipment rated?’ to ‘was the equipment right, traceable, inspected, understood and used by competent people?’ A safe lifting operation does not begin when the crane moves or the chain tightens. It begins when somebody decides what to buy, what standard to require, what documentation to accept, what inspection regime to follow, and who is competent to use it.”
The main presentation of the day introduced attendees to the ‘Forging the Future of Lifting ’ project, demonstrating how it is driving digitalisation and safer lifting practices across operations.
Leanne Whitehurst-Maiden, national digitalisation manager at RSS, said: “Sheffield Forgemasters carries out many complex operations that place significant demands on lifting equipment; it is a perfect case study of what can be achieved through digitalisation. Key components of our programme include development of bespoke training courses; integration of digital systems, offering birth to death traceability; and roll-out of digital calculators to better support the selection of appropriate equipment.”
The launch included an interactive workshop, allowing attendees to participate in examining physical failures along with videos demonstrating incorrect arrangements. The workshop offered visitors a preview of the bespoke training courses currently being developed as part of the project. Feedback was overwhelmingly positive, with many attendees commenting that they had gained valuable insights and a fresh perspective on aspects of lifting operations they had not previously considered.
Sheffield Forgemasters’ new machine shop forms part of the company’s £1.3 billion recapitalisation programme; the 30,000 m² facility will house some of the world’s most advanced large-scale machine tools. Construction began following planning approval in early 2025, with the building expected to complete by the end of 2028. Designed to support the machining of complex forgings and castings for UK defence programmes, the landmark development will also incorporate heavy-duty overhead cranes and material handling systems capable of moving some of the largest single steel components manufactured in the UK.
Part of the ambitious plans include the full scale roll-out of the ‘ Forging the Future of Lifting ’ project to ensure fully digital lifting operations across the new machine shop. The concept has already been introduced across other areas of the site in preparation for the new machine shop opening. This will ensure lifting operations are fully digital, integrating safety-critical documentation, pre-use checks, lift plans, calculators, post-lift reviews and data analysis, to improve future lifts.
Whitehurst-Maiden added: “Following the workshop with a tour of the site put everything into perspective. The new facility demonstrates an impressive scale of investment and capability and equips the operation for future growth. It is particularly significant as Sheffield Forgemasters celebrates its 250th anniversary this year, demonstrating how the company continues to honour its rich heritage while embracing innovation and investing confidently in the future. We are honoured to be able to support them on this journey towards safer lifting practices through digitalisation.”
Daniel Jennett, health, safety and environmental manager at Sheffield Forgemasters, said: “Digitalisation is changing the way organisations manage all aspects of lifting operations, ensuring safety and efficiency. We’ve seen first-hand how digitalisation can improve traceability, provide greater visibility of equipment, and give users more confidence in the information they rely on.”
Ahead of the site tour, Chris Humphries from McLaughlin & Harvey, a specialist construction and civil engineering contractor, briefed attendees on the project’s progress, outlining its timeline, key challenges and notable successes. The day concluded with an ‘Ask the Experts’ panel session, where representatives from LEEA, RSS, Sheffield Forgemasters and participating suppliers answered questions from attendees. The discussion provided a fitting finale to the event, with particular emphasis placed on the importance of carrying out and digitally recording pre-use inspections to support safer lifting operations. The strong engagement throughout the day was reflected in the number of attendees who requested access to the training materials to help strengthen practices within their own organisations.
Attendees visited Sheffield Forgemasters’ new machine shop
- A follow-up event is planned in six months’ time to review progress, share further developments and continue the industry’s digitalisation journey.
