Cranes are complex, powerful machines that allow us to easily move heavy loads around the jobsite. They are essential to many modern construction and industrial operations, but we must remember that the stakes are high when working around cranes. A crane’s ability to lift heavy loads high into the air makes them a potential safety hazard and therefore, they must be treated with the utmost respect. Like many safety topics, crane safety is a broad topic that would a require a multi-day course to cover every detail. This crane safety toolbox talk covers some of the key aspects of crane safety for operators, supervisors and ground crews.
Working Around Cranes
Stay Alert and Communicate
Working near cranes means always being alert. It’s not just the crane operator’s job to watch out; ground workers play a vital role too. Remember, never walk under a suspended load and always be aware of the crane’s swing radius. Clear communication between the crane operator and the ground crew is crucial. Whether it’s hand signals or radios, make sure the message gets across loud and clear. Be sure to designate one person to signal and / or radio the crane operator to prevent confusion. If other crews are working nearby, ensure they know lifting operations are in progress and they know to stay out from under the swing radius.
Suspended Load Safety
Operating in crane zones involves managing the risks of overhead suspended loads. Be sure to use safe rigging practices to keep loads balanced and secure. Do not walk under suspended loads. Move to a safe location when a load is being swung over your work area. Plan crane operations to reduce the frequency of loads swinging over crews and equipment.. Always be aware that debris can fall from even correctly rigged loads; stay vigilant and cautious. A small amount of wet concrete or dirt falling off a suspended load will accelerate rapidly and could impact the ground with a substantial amount of force.
Safe Crane Operation
Crane Training and Certifications
OSHA requires that only competent, trained employees operate cranes. Best practice is to ensure crane operators complete a crane operator certification course. It is essential that crane operators not only know how to operate the controls, but also understand the concepts behind what makes a crane work and how they could potentially tip over. OSHA also requires that cranes be inspected annually and before each use by a competent person. Best practice is to have a 3rd party inspect your cranes at least once a year. Trained operators need to conduct inspections before each use. Pay special attention to cables, booms, outriggers, hooks, and rigging.
Develop Lift Plans for Crane Safety
Every operation involving cranes should be planned out in detail. The consequences of overturning, hitting power lines, or dropping loads are often serious injury or death. A competent person should review the load chart prior to each lift. Ensure the proper load chart is being used for the model and configuration of your crane. When calculating loads, be sure to include the weight of cable, hooks, and rigging.
Check the weather in your area before each lift, paying special attention to the wind speeds. Walk the site and layout center-pin and outrigger location. Verify the distance from the center of the load to the center-pin and ensure there is space for the boom and counterweights. Check the ground to ensure it is stable enough to support the counterweights and verify you have the correct outrigger pads or crane matts. In some cases, a professional engineer may be need to certify that the ground is stable; especially if the crane will be near a slope, open excavation or underground structure. Critical lifts are defined as crane lifts that exceed 75% of the rated capacity. The factors listed above are even more important during critical lifts, as even a small calculation could lead to catastrophe.
Crane Safety Around Power Lines
Power lines are another hazard that commonly lead to accidents during crane operations. Take them into account when developing your lift plan. Remember, you don’t need to contact a power line to cause an accident. High voltage power has the ability to arc over a long distance. Stay at least 10 ft. away from distribution lines carrying 50,000 volts or less. Transmission lines usually carry more 50,000 volts and need a greater distance. Use the local power company as a resource. They will be able to confirm voltage and may be willing to shut off power or insulate power lines.
Other Crane Safety Tips
- Hydraulic booms should not be extended or retracted when under load. Boom up or down instead.
- Modern cranes usually come equipped with alarms and other features to signal when the crane is at maximum design capacity. Do not rely on these safety features! Use load charts and adequate planning to keep crane operations safe.
- Designate a competent, trained person to signal the crane operator.
- If weather, ground conditions, load capacity or any other factor are in doubt, do not make the lift! It is always worth taking the time to ensure the operation is safe. This is especially true when it comes to crane operations.
Conclusion – Crane Safety Toolbox Talk
This crane safety toolbox talk covered some of the most essential safety items for crane operations. Crane safety is a broad, technical topic and we have not covered every aspect in our toolbox talk today. That is why it is essential that supervisors, operators, riggers and signalmen be trained. Cranes are wonderful machines that are essential to many aspects of our industry, but we must always be aware of the potential dangers. Teamwork planning and training are the keys to safe crane safety.