Cranes Are Often The Most Powerful Equipment On The Job
Cranes are some of the most powerful and essential machines on construction sites. Their ability to lift and move heavy loads makes them indispensable, but this power also brings significant risks if not handled properly. Operators must be trained and certified to ensure that everyone on site remains safe.
According to OSHA and BLS data, about 40 construction workers lose their lives each year due to crane-related accidents. To mitigate these risks, cranes weighing over 2,000 pounds are strictly regulated, and operators must hold a valid certification from the National Commission for the Certification of Crane Operators (NCCCO). Companies operating cranes are legally responsible for any damage or injury caused, which is why many opt for specialized insurance coverage.
Crane Safety Toolbox Talk
Checklist of critical items to monitor before moving a load
- Inspect the area for overhead obstructions such as power lines, trees, or structures.
- Ensure slings, chains, and straps are rated for the load and have clear tags showing their safe working limit.
- Identify and mark pinch and crush points around the crane and the landing area with paint or chalk.
- Set up barriers in the swing radius of the crane to prevent unauthorized access.
- Confirm the load is balanced and free of obstructions in its path.
- Follow a detailed lift plan for all major lifts and share copies with the crew.
Checklist of critical items to monitor while moving a load
- Never allow anyone to stand under a suspended load.
- Keep all personnel at a safe distance during lifting operations.
- Operators must remain focused and avoid distractions like phone calls or texting.
- A trained signalman is required to communicate with the operator using standardized hand signals.
- Only one person should give signals at a time unless it's an emergency situation.
- Use an air horn to alert people when a lift is in progress.
- Avoid raising the load higher than necessary.
- Never leave a load hanging in the air unattended.
Toolbox Talk Outline
- Start by discussing the task at hand.
- Go over the pre-lift and during-lift checklists.
- Review safety protocols, including PPE, first aid, and emergency procedures.
- Encourage questions and feedback from the team.
- Conduct a quick quiz to ensure everyone understands the key points.
Safety Equipment - Signs, Stickers, Air Horns & Lights
Safety Signs and Stickers
Clear and visible safety signs are crucial for communicating hazards on a job site. OSHA and ANSI guidelines recommend specific visual cues for crane areas. These signs are typically made from durable materials like vinyl, polyester, or aluminum and can be found online or at local suppliers.
In multilingual areas, consider using bilingual signs to ensure all workers understand the warnings.
Sample Safety Signs
Source: SafetySign.com
Note: Equipment Radar is not affiliated with or sponsored by SafetySign.com.
Air Horns and Audible Signals
Before a lift, use an air horn or audible alarm to notify nearby workers. After the lift, use an "all clear" signal. Different horn patterns help distinguish between warning and clearance.
These signals are especially important because not everyone may see the crane in action.
Safety Lights
Lighting is essential for visibility, especially in low-light conditions or bad weather. Warning lights can be placed around the crane to alert workers of its presence and the associated risks.
Transportation
Transporting large cranes requires careful planning, especially in busy urban or industrial areas. Measure the intended route and account for extra space around corners and tight spots.
Having spotters on either side of the crane can help guide the driver safely through narrow passages. Always maintain communication between the driver and spotters.
Oversized load signs and flags are often required, and in some cases, police escorts may be necessary. Check local regulations to ensure compliance.
Lift Plan
A lift plan is similar to an architectural blueprint—it outlines how a lift will be executed safely. It includes details such as load weight, center of gravity, dimensions, lifting points, and risk mitigation strategies.
Engineers or experienced professionals typically create these plans, and they should be shared with all involved parties. Updates should be communicated promptly to ensure everyone follows the same procedure.
OSHA Crane Safety Hand Signals
Effective communication between the crane operator and the signal person is vital. OSHA has established standard hand signals to ensure clarity and safety. Below are some of the most commonly used signals.
With arm extended horizontally to the side, palm down, arm is swung back and forth.
With both arms extended horizontally to the side, palms down, arms are swung back and forth.
With upper arm extended to the side, forearm and index finger pointing straight up, hand and finger make small circles.
With arm extended horizontally to the side, thumb points up with other fingers closed.
With arm extended horizontally, index finger points in direction that boom is to swing.
With hands to the front at waist level, thumbs point at each other with other fingers closed.
With arm extended horizontally to the side and thumb pointing up, fingers open and close while load movement is desired.
Hands held together at waist level.
With arm and index finger pointing down, hand and finger make small circles.
With arm extended horizontally to the side, thumb points down with other fingers closed.
With hands to the front at waist level, thumbs point outward with other fingers closed.
With all fingers pointing up, arm is extended horizontally out and back to make a pushing motion in the direction of travel.
With arm extended horizontally to the side and thumb pointing down, fingers open and close while load movement is desired.
A hand is placed in front of the hand that is giving the action signal.
With arm bent at elbow and forearm vertical, elbow is tapped with other hand. Then regular signal is used to indicate desired action.
Rotate fists around each other in front of body; direction of rotation away from body indicates travel forward; rotation towards body indicates travel backward
A hand taps on top of the head. Then regular signal is given to indicate desired action.
Indicate track to be locked by raising fist on that side. Rotate other fist in front of body in direction that other track is to travel.
With palm up, fingers closed and thumb pointing in direction of motion, hand is jerked horizontally in direction trolley is to travel.
Source: Full OSHA Crane Guidelines
Crane Rental
Many crane rental companies offer more than just equipment—they provide safety resources, licensed operators, and even transportation services. Some can also assist with creating a lift plan or refer you to a qualified engineer.
Every project is unique, so it’s always best to consult with your rental company early in the planning process to ensure everything goes smoothly.
Resources
12 types of cranes
OSHA Crane, Derrick and Hoist Safety
Crane safety video
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