Cranes Are Often The Most Powerful Equipment On The Job
Cranes are typically the largest and most powerful machines found on construction sites. Their immense size and lifting capabilities make them essential for moving heavy materials, but these same features also pose significant risks if not handled properly. Operators must be well-trained to ensure that everyone on site remains safe, from workers to nearby bystanders.
According to data from the Bureau of Labor Statistics (BLS) and the Occupational Safety and Health Administration (OSHA), about 40 construction workers lose their lives each year due to crane-related accidents. To prevent such tragedies, cranes weighing over 2,000 pounds are subject to strict regulations. Operators must be certified by the National Commission for the Certification of Crane Operators (NCCCO). Additionally, companies are legally responsible for any damage or harm caused by crane operations, which often leads to the purchase of specialized insurance coverage.
Crane Safety Toolbox Talk
Checklist of critical items to monitor before moving a load
- Check for overhead obstructions like power lines, trees, and structures before starting the lift.
- Ensure that slings, chains, and straps have proper load ratings and safety tags indicating their maximum working capacity.
- Identify and mark areas where pinching or crushing hazards may occur, both around the crane and at the landing zone.
- Establish a clear barrier around the crane’s swing radius to prevent unauthorized access during operation.
- Confirm the load is balanced and free of obstacles in its path of movement.
- Develop and share a detailed lift plan with all relevant personnel. Any changes should be communicated immediately.
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 from the crane during lifting operations.
- Crane operators must remain focused and avoid distractions like phone calls or texting.
- A trained signal person must be present, using standardized hand signals to communicate with the operator.
- Only one person should give signals at a time unless it's necessary for safety reasons.
- Use an air horn to alert people when a lift is in progress.
- Avoid raising the load higher than needed.
- Never leave a load hanging in the air unattended.
Toolbox Talk Outline
- Start with a brief discussion of the day’s tasks.
- Go over the pre- and during-lift checklists.
- Cover safety concerns, including PPE, first aid, emergency procedures, and environmental hazards.
- Encourage open dialogue and questions from the crew.
- Consider a short quiz to ensure everyone understands the key points.
Safety Equipment - Signs, Stickers, Air Horns & Lights
Safety Signs and Stickers
Safety signs and stickers are crucial tools for communicating risks on a job site. OSHA and ANSI provide guidelines for effective signage, especially for cranes. These signs help raise awareness among workers and visitors, reducing the likelihood of accidents.
Common materials used for crane warning labels include vinyl, polyester, aluminum, and plastic. Many suppliers, such as SafetySign.com and Amazon, offer a variety of options. In multilingual areas, consider using bilingual signs to ensure clarity for all workers.
Sample Safety Signs
Source: SafetySign.com
Note: Equipment Radar is not affiliated with or sponsored by SafetySign.com.
Air Horns and Audible Alarms
Before lifting, use an air horn or audible alarm to notify nearby personnel and clear the area. After the lift is complete, use an “all clear†signal. Different horn patterns can be used for different stages of the process.
These auditory cues are important because not everyone may be directly watching the crane, especially in busy environments.
Safety Lights
Proper lighting is essential for visibility, especially in low-light conditions or bad weather. Warning lights help distinguish the crane from its surroundings, making it easier for workers to spot and avoid potential hazards.
Installing spotlights around the crane can help increase awareness of its presence and reduce the risk of accidents.
Transportation
Transporting large cranes requires careful planning, especially in urban or complex industrial settings. It's vital to study the route beforehand and measure all dimensions to ensure the crane can move safely. Extra space should be accounted for around turns and tight spaces.
Having spotters on either side of the crane during maneuvering can improve safety. The driver and spotters should maintain constant communication through visual or auditory means.
Oversized load warnings, such as flags and signs, are often required by law. Some routes may even need police escorts or special permits. Always check weight limits, especially when crossing bridges or elevated roads.
Lift Plan
A lift plan is similar to an architectural blueprint—it requires careful design and preparation. Engineers create these plans based on specific job requirements, ensuring all aspects of the lift are considered.
Key elements of a lift plan include:
- Load weight and crane capacity
- Center of gravity location
- Maximum load dimensions
- Lifting points and rigging gear
- Height restrictions and obstacles
- Risk assessment and mitigation strategies
- Detailed method statement, including costs and site impact
Once created, the lift plan must be shared with all involved parties. Changes should be updated and distributed promptly to avoid confusion.
OSHA Crane Safety Hand Signals
Clear communication between the crane operator and signal person is essential. OSHA has established standard hand signals that must be followed to ensure safety and coordination.
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 can also provide safety resources, qualified operators, and transportation services. Some even assist with creating lift plans or offering referrals. Since every project is unique, it’s always best to consult with your rental provider early in the planning stage.
Resources
12 types of cranes
OSHA Crane, Derrick and Hoist Safety
Crane safety video
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