In a construction site with proper safety practices, a crane operator executes each lift with the right knowledge and tools. Cranes come with strict safety standards, and you’ll need to abide by OSHA and industry regulations to operate them. For example, all components must be in proper working order, and everyone should be trained properly in how to use it.
This guide will explain what you need to know about crane safety, from conducting regular inspections to proper communication techniques and common hazards. We’ll also show you helpful tips and resources for keeping everything on track and protecting everyone on-site.
What is crane safety?
Crane safety is all about having procedures, protocols, and inspections in place so cranes are operated properly and effectively, preventing accidents and injuries. After all, cranes are often used in industries like construction and manufacturing to handle heavy loads. If they aren’t maintained and operated properly, the consequences can be severe.
A crucial part of crane safety is thoroughly inspecting cranes before, during, and after each shift. Inspections can diagnose problems early and prevent dangerous workplace accidents from occurring. Ensuring that cranes are working properly and optimally helps keep bystanders safe as well.
Regular crane inspections lower the chance of costly fines and repairs, and keep you compliant with legal standards and regulations issued by the Occupational Safety and Health Administration (OSHA). Crane inspections are conducted by trained and experienced safety officers.
Types of crane inspections
According to OSHA and Crane Manufacturers Association of America (CMAA) standards, designated managers and supervisors must perform three different types of inspections using an OSHA crane inspection checklist. These should be regularly performed as long as cranes are in use:
Initial inspection
All new and altered cranes are required as per OSHA Standard 1910.179 to undergo inspection before they can be used. Appointed personnel must supervise the installation and inspect the functionality of crane components.
Tasks here include:
- Check the overall crane structure for any deformities, cracks, or damage
- Conduct load tests to check if the crane can handle the weight it’s designed for
- Inspect control systems, like hoists, trolleys, and bridge travel mechanisms
- Confirm that safety devices are present and working properly, including limit switches, emergency stops, and safety latches
- Verify if the braking system can effectively stop and hold the rated load
- Review the manufacturer’s installation and operation manual to see if all recommended procedures have been followed
Frequent inspection
Frequent inspections are conducted at daily, weekly, or monthly intervals, depending how often your crane is used. Make sure these inspections include the date and the inspector’s signature. Things to assess during frequent inspections include:
- Misconfigurations that affect the crane’s optimal performance
- Deterioration or leakage in various parts like hydraulic systems, drain pumps, valves, or tanks
- Damages, like a cracked or deformed hook
- Deformities and damages in the hoist chains
- Excessive wear of components
- Whether the wire rope reeving system is still working as described in the manufacturer manual
Periodic inspection
Periodic inspections are similar to frequent inspections because they also depend on how often the crane is used. For example, cranes that haven’t been used for a month but were used within the last six months must undergo a thorough periodic inspection before they can be used again.
Some of the items to inspect are the same as in frequent inspections. But there are a few additional elements. During a periodic inspection, you need to:
- Inspect any cracked, deformed, or corroded parts
- Check any loose bolts or rivets, worn or distorted pins, cracked or worn sheaves and drums, clamping devices, bearings, gears, rollers, and shafts
- Check for excessive wear on the brake and clutch system, ratchets, and paws
- Look for inaccuracies in different indicators (like the fuel gauge)
- Ensure that there are no faulty or unsafe parts such as leaking exhaust
Two most common hazards to address for crane safety
According to the U.S. Bureau of Labor, there are an average of 42 deaths as a result of crane accidents each year. Knowing the hazards involved when operating or working with cranes can save your or your colleagues’ lives.
Here are the most common safety hazards and their causes:
Electrical hazards
Around half of accidents that involve overhead cranes happen when metal parts touch a power source, such as a high-voltage power line. When moving materials underneath or near cranes, there’s a high chance that a crane’s hoist line will come into contact with electricity sources.
When this happens, anyone near the machine is at risk of electrocution. It’s important to map out work routes before you begin a job, so these collisions can be avoided.
Falling loads
Falling loads are the most common and most dangerous hazards. A falling load can lead to injuries and death, as well as damage buildings and properties. These damages can cost you lots of money and time.
Falling loads are a result of:
- Incompetence – Crane operators should receive adequate training so they can do their jobs safely and competently
- Mechanical failure – Prevent mechanical failures with regular and thorough crane inspections
- Two blocking – Two blocking is when an uppermost hoist line part comes into contact with the upper block boom tip, increasing tension on the line and causing loads to fall
- Slipping – Make sure you secure loads properly to avoid slipping
- Overloading – If a load exceeds the equipment’s capacity, it’s subject to stress that can damage the machine
Best practices for crane safety
Keeping in mind the hazards and inspection tasks listed above, check out these practical tips for keeping your crane operations safe and efficient:
1. Be diligent with inspections and maintenance
You must do thorough pre-operational checks before every shift, with clear documentation all throughout. Look for signs of wear or damage on critical components like brakes, hoists, wire ropes, and hooks. Make sure that all control systems respond properly, including emergency stops.
Aside from these, cranes must also go through regular maintenance. This way, you’ll be able to identify mechanical issues like worn-out parts or fluid leaks before they escalate to bigger problems.
To make inspections and maintenance part of your routine, you can adapt these crane safety checklist templates. They cover diverse scenarios, including different types of cranes, and they’re easy to edit based on your safety processes.
2. Crane operators must be certified and trained
According to OSHA standards, only certified and trained personnel are allowed to handle cranes. In fact, this is included in the main requirements:
Going through certification ensures that operators understand the limits of the crane, how to lift loads properly, and how to communicate with the team on the ground.
Even though operators are already certified, it’s still a good practice to give regular training sessions and refresher courses so everyone is up-to-date on safety protocols and new equipment features. You can also include the whole crew in the training–including riggers, signal persons, and ground workers–so they know their roles well.
3. Never exceed load limits
Overloading a crane is one of the leading causes of accidents here. Always check the load chart and verify the weight of the object being lifted so you don’t go beyond the crane’s weight limits. Operators should understand the crane’s load capacity, which can depend on boom length, lift height, and configuration.
Use reliable measuring tools to get the weight of the load load, and never guess. If a load feels too heavy or unstable, it’s better to split it into smaller lifts or use a crane with a higher capacity.
4. Check ground conditions and weather
Stable, level ground is a must for crane safety. Always assess the terrain before setting up a crane to reduce the risk of tipping. If the ground isn’t stable, add heavy-duty mats, cribbing (stacking sturdy wood or metal blocks), or other stabilization measures so the crane doesn’t shift while it’s in use.
The weather can also affect how stable the ground is, which is why OSHA recommends avoiding using cranes when it’s raining or snowing heavily. These make the ground unstable and slippery, and there’s also reduced visibility.
5. Secure the load properly
Before any lift, the load should be securely rigged, meaning it’s fastened with the right equipment (like slings, chains, or hooks) and all of these are in good condition. Use certified rigging gear that matches the load’s weight and type.
It’s also critical for the load to be evenly balanced. Otherwise, it might shift or swing during lifting, which makes it more likely to damage the crane or even fall. Always conduct a test lift to check balance before moving the load.
6. Maintain clear communication
There should be clear communication between the crane operator and the ground crew during the whole time. OSHA actually put up a set of standardized hand signals that crane operators can use, including for hoisting, lowering, moving the boom, and stopping. The team can also use two-way radios to verbally communicate.
Assign a signal person whose only job is to communicate with the operator. This person should be able to see both the crane and the load clearly so they can give accurate instructions.
Workflow automation software for crane safety checklists
Crane safety takes into account a lot of variables in order to make sure the equipment is working properly and protocols are followed. By using workflow automation software to digitize crane safety checklists, you can streamline the process. Use Lumiform’s desktop and mobile app to automate the inspection and issue resolution processes, saving yourself time and improving the quality of checks.
Lumiform’s crane safety software does this by:
- Giving you access to premade and standardized crane safety checklists, which you can complete anywhere thanks to the mobile app
- Allowing inspectors to take photos or write notes that provide more context in case of damages
- Streamlining corrective actions by letting you assign and track them in a few clicks
- Sending you real-time data whenever an inspection is completed, and turning this data into detailed analytics automatically