Crane Safety
Published: February 9, 2019

Crane Safety

The invention of cranes made things easy for humankind because without them, loading, unloading, and lifting had to be done by human hands, would consume more time, and the entire system was not efficient at all. Cranes are a marvel of engineering, and an essential component of many industries including construction, manufacturing, warehousing, and more. Operating a crane takes extensive training, and following set standards to ensure both the crane operator, and those in the surrounding area, are safe. Crane safety is an important component of overall workplace safety, and doing it right can mean the difference between life and death in many cases.

Common Crane Hazards

Crane operators, and those working around them, should be taught what the most common crane hazards are. Being aware of these risks will help ensure that everyone is watching out for them, and taking steps to avoid them whenever possible. The following are some of the hazards that all crane safety plans should take into account because of how frequently they can occur, and how serious they can be:

  • Electrical Hazards - Cranes operate at great heights, which put them in a terrible position for accidently hitting electrical lines. The metal in the crane is an excellent conductor, and can cause fatal electrocution. Crane operators must be aware of where every electrical line is at all times. Use a spotter when working near power lines and use non-conductive tag lines.
  • Materials Falling - Every load that a crane lifts needs to be properly secured. But even when the loads are secured, there is always a risk of something falling off. Those below the crane should avoid working in the area, and wear hard hats and other appropriate PPE when it is unavoidable.
  • Overloading a Crane - Cranes can lift an astounding amount of weight, but there are limits. Crane operators, and those that load cranes, need to know precisely how much weight it can handle, and exactly how much weight they have added at any given time. Overloading a crane can cause it to tip over, or to drop the load, which can have devastating consequences.
  • Crane Movement (pinch points) - Cranes often need to twist or move to get the load where it needs to go. This can create pinch or crush points where someone could be seriously injured.
  • Dropped Loads - If a crane drops its load, whatever is under it will be crushed. Even vehicles or structures can be crushed from the impact of a heavy load dropped from a significant height. Nobody should work directly under a crane load for any reason, even with PPE.
  • Oil Leaks / Fuel Spills – Cranes bring oil, hydraulic oil and diesel to the workplace. A spill kit and spill response plan should be developed.

Developing Crane Safety Procedures in the Workplace

Having a detailed crane safety program in the workplace is an important step for all employers where cranes are used. This can start by identifying potential crane related hazards, and continues with finding ways to eliminate the hazards, or compensate for them in some way.

All workplace safety is important, but crane safety in particular is critical because of how devastating accidents related to cranes can be. The following are some key areas that should be included with any good crane safety plan.

Safety for Different Types of Cranes

There are several different types of cranes used in industries today, and each of them will have a different set of hazards that need to be accounted for. Understanding what type of crane is used in a given area, and how to improve safety for that specific type, is a critical component of an overall crane safety plan. Some of the most common types of cranes are:

  • Tower Crane - Tower cranes can reach very high heights (265+ feet) and are commonly used in construction of skyscrapers or other buildings. These cranes can be secured at the ground, or attached to the top of a structure to aid in its completion.
  • Gantry Crane - A gantry crane is fixed in one spot and gets support from the structure it is fixed to. These cranes are common in places like trainyards, shipyards, and factories.
  • Rough Terrain Crane - Cranes equipped with treads rather than tires are important for construction sites with unpaved or otherwise rough terrain. It is critical to ensure the crane is secured safely before loading it to avoid accidents.
  • Aerial Crane - An aerial crane, or sky crane, is attached to a helicopter. The wind caused by the helicopter makes securing loads properly especially important.
  • Floating Cranes - Cranes that are based on a ship or platform in the water are known as floating cranes. In some cases, these cranes can be unstable due to waves, which must be taken into account when planning for their use.
  • Vehicle Mounted Cranes - A crane can be mounted on a vehicle to make it more mobile for easier use. In most cases, the vehicle will be a large truck equipped with heavy outriggers to stabilize the crane while it is in use.

Safe Operating Practices for Operators:

Whenever any crane is used, the following safe practices (as a minimum) shall be observed:

  1. Always check warning devices and signals before use.
  2. Always document and maintain inspection records.
  3. Always ensure cranes shall not be loaded in excess of their rated capacities.
  4. Always ensure the new location support the weight.
  5. Always keep employees clear of loads about to be lifted and suspended loads.
  6. Always keep suspended loads clear of all obstructions.
  7. Always lockout before maintenance or repairing cranes.
  8. Always position the hook directly over the load before lifting.
  9. Always test brakes by a short lift to ensure control.
  10. Before being lifted, loads will be checked for proper balance.
  11. Follow the manufacturer’s recommendations.
  12. Frequently inspect cranes exposed to adverse conditions.
  13. Hands must not be placed between the suspension means and the load during lifting.
  14. Know where you’re going to set the load down.
  15. Know your travel path in advance of the lift.
  16. Loads will in all cases be properly balanced to prevent slippage.
  17. Move loads only after being signalled by the designated, qualified signaller.
  18. Never allow riders on loads or hooks.
  19. Never allow unauthorized persons to operate cranes.
  20. Never attempt to operate a crane or hoist that is suspected to be unsafe.
  21. Never carry loads over workers.
  22. Never carry loads past workers (they must yield right of way).
  23. Never use cranes that are damaged or defective in any way.
  24. Operators must watch the signallers.
  25. Shock loading is prohibited.
  26. Signallers must keep line of sight with the operator.
  27. Signallers must watch the load.
  28. Test all hoist controls and brakes at the beginning of each shift. 

Safe Operating Practices for Signallers

Whenever any crane is used, the following safe practices (as a minimum) shall be observed:
  1. Ensure that only one person is the designated signaller.
  2. Ensure the operator acknowledges every signal.
  3. Follow the manufacturer’s recommendations.
  4. Know the new location will support the weight.
  5. Maintain line of sight with the operator.
  6. Operators must watch the signallers.
  7. Plan in advance where the load is going.
  8. Stop the operation any time comprehension is lost.
 

Crane Inspection Checklist

Making sure that a crane is in proper working order before it is used is essential. If anything isn't working right, it can cause serious accidents and injuries to those in the area. All crane safety plans should include a crane inspection list that the operator (or other designated individual) will need to go through before operating the crane.

The exact details of a crane inspection list will vary somewhat based on the type of crane and other information, but in general each list should have the following categories covered:

  • Hook - This category will check things like the opening of the hook, checking for cracks or corrosion, how much wear is on the throat, and other details.
  • Wire Rope - Check that the wire rope is in good working condition. Look for breaks, corrosion, kinks, bird cage, protrusion and any other signs of damage. Also check for the reduction in size of wire rope diameter.
  • Wedge Sockets - Looking at the wire rope size, the dead end of a wire rope, and ensuring the wire rope is properly secured.
  • Sheaves - Check to ensure the wire rope is seated into the sheaves, that the keepers are in good working order, the bolts are tightened correctly, and for any signs of damage or wear.
  • Boom - Look for hydraulic leaks, watch for lattice extension issues, and check all around the boom for bent, buckled, or cracked panels.
  • Fluids - Checking all the fluids in the crane to ensure they are at the necessary levels.
  • Tires - Tires must be inflated to the required levels, and should not have any cuts, bulges, or signs of wear past the normal expected life of the tire.
  • Safety Devices - This includes the anti-two blocking device, overload device, slewing device, boom limits, etc. Ensure that all this devices are working properly prior to use.
  • Other - Any other things that need to be checked on a given crane before it is operated.

A crane inspection checklist can either be printed off on paper, or a digital version. Someone should actually check off each section of the list signifying that they have been checked before the crane is put into use on the jobsite.

Inspection documentation:

Cranes inspections will be documented as having been inspected. Scheduled inspections will be documented as having been conducted.
  1. Identify items that were inspected.
  2. Show the status of the inspected items.
  3. Provide the signature of the inspector.
  4. Show the date.
  5. File it and maintain it.
  6. Review the manufacturer’s specific inspection requirements.
 

 

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