Cranes Are Often The Most Powerful Equipment On The Job
In construction and industrial environments, cranes are among the most powerful machines. Their ability to lift and move massive loads is essential for many projects, but this power also comes with significant risks. Proper training, clear communication, and strict safety protocols are crucial to prevent accidents and ensure the safety of everyone on site.
According to statistics 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 incidents. Because of this, cranes weighing over 2,000 pounds must be operated by certified professionals through the National Commission for the Certification of Crane Operators (NCCCO). Companies that use cranes are legally responsible for any injuries or damage caused, which often leads them to purchase 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, and structures.
- Ensure that slings, chains, and straps have proper load ratings and identification tags.
- Identify and mark pinch and crush zones around the crane and the load area.
- Set up barriers to protect the swing radius and prevent unauthorized access.
- Confirm the load is balanced and free of obstructions in its path.
- Develop and share a detailed lift plan with all involved personnel.
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 should stay focused and avoid distractions like phone calls or texting.
- A trained signal person must be present and use standardized hand signals.
- Only one person should give signals at a time to avoid confusion.
- Use an air horn to alert others when a lift is in progress.
- Avoid raising loads unnecessarily high.
- Never leave a load hanging in the air unattended.
Toolbox Talk Outline
- Review the day’s tasks and potential hazards.
- Go over the pre-lift and during-lift checklists.
- Discuss PPE, first aid, emergency procedures, and environmental risks.
- Allow time for questions and feedback from the crew.
- Conduct a short quiz to ensure understanding of the safety guidelines.
Safety Equipment - Signs, Stickers, Air Horns & Lights
Safety Signs and Stickers
Clear and visible safety signs are essential for communicating risks on a job site. OSHA and ANSI provide guidelines for using these signs effectively. Common materials include vinyl, polyester, and aluminum, and they can be purchased from suppliers like SafetySign.com and Amazon. Bilingual signs are recommended for areas where multiple languages are spoken.
Air Horns and Audible Alarms
Before lifting, use an air horn or radio to notify nearby workers. After the lift, signal “all clear†again. Different horn patterns help distinguish between start, stop, and finish. These signals are especially important in areas where visibility is limited.
Safety Lights
Lighting is crucial for ensuring visibility, especially in low-light conditions or bad weather. Warning lights can be placed around the crane to highlight its presence and reduce the risk of accidents.
Transportation
Transporting cranes requires careful planning, especially in urban or complex environments. Always measure the intended route and account for extra space when turning or navigating tight spaces. Spotters should be used to guide the crane safely. Oversized load signs, flags, and sometimes police escorts may be required depending on local regulations.
Lift Plan
A lift plan is a detailed document prepared by an experienced engineer. It includes information about the load weight, center of gravity, dimensions, lifting points, rigging gear, height restrictions, and risk assessments. This plan must be shared with all team members and updated if changes occur.
OSHA Crane Safety Hand Signals
Crane operators and signal persons must use standard hand signals to communicate. Below are some of the most common OSHA-approved 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, certified operators, and transportation services. Some even assist with creating lift plans or offering referrals. Every project is unique, so it's always best to consult your rental provider early in the planning process.
Resources
12 types of cranes
OSHA Crane, Derrick and Hoist Safety
Crane safety video
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