This article looks at the hazards in crane lifting. Find out more about the    most common crane hazards and crane safety tips when planning lifting operations.

What are the Most Common Crane Hazards?

Much like working with any other large machinery, many potential hazards are involved when working with cranes, whether tower cranes, mobile cranes, crawler cranes, gantry cranes or any other type.

If you or your operators aren't familiar with safe working practices, there is a real threat of irreversible damage to buildings and materials, injury and even fatalities.

Crane Safety Checklist

 So, to help you guarantee a safe working environment when working with cranes, here are some of the most common crane hazards you could face:

Falling Loads

This shouldn't be a surprising hazard to find on a list of the main hazards of cranes. Given that overhead cranes are used to lift heavy loads into the air, the threat of falling materials from a suspended load is incredibly dangerous.

The damage a falling load can cause is unlimited, from the load hitting structures or damaging goods to serious injuries and fatalities. 

Most falling loads from cranes are due to:

Operator incompetency - you must ensure that those operating your cranes have adequate training to do so safely. 

Slips - unsecured loads are far more likely to fall. Making sure all material is properly secured is essential for safe work.

Mechanical failure - routine inspections, regular maintenance and repairs and having your cranes visually checked are the best ways to ensure your crane is safe to use, reducing the chance of mechanical failures. 

Two blocking - this occurs when the upper hoist line component, whether a hook block, load block or overhaul ball, touches the upper block, boom tip or other crane components. This generates tension in the line, which could lead to falling loads or crane components. 

Electrical Hazards

Those at the highest risk of electrocution here are those touching or close to the crane when it comes into contact with the power line. 

herefore, you can see how one incident can lead to multiple deaths or injuries. Roughly 200 fatalities are caused by this hazard every year, so proper prior planning is essential to ensure the safety of your workers. 

Crane Overload

Failing cranes or cranes tipping, in most cases, are due to the crane being overloaded. Again, you must have competently trained operators working on cranes at all times to ensure this doesn't happen. You should avoid exceeding the crane's operational capacity at all costs, as it can generate significant structural stresses and damage. 

Overloading the crane can happen if:

1. You hoist loads over the crane's capacity.
2. Drop or swing your load suddenly.
3. Side-load your boom.
4. Drag loads.
5. Use defective components. 

Crane Safety Tips

As you can probably tell, working with cranes is inherently hazardous. However, there are ways to reduce the risks involved to a suitable level and take safety precautions to keep your workers safe. 

You can improve operational and equipment safety by:

Training employees - all employers must provide appropriate health and safety training for all their workers in whatever work they are doing, which is especially important for crane operators. Not only will this reduce damage, injuries and fatalities, but it will boost workplace safety, which improves job satisfaction, leading to greater productivity and profits. 

Safety protocols - as part of their training, you must insist that your workers never stand underneath loads being lifted and that your operators never lift a load above another employee. Essentially, there should be exclusion zones around your cranes that no one can walk through with moving materials nearby. 

Follow regulations - when operating cranes, you must adhere to the Lifting Operations and Lifting Equipment Regulations 1990 (LOLER). 

Maintenance - regularly scheduled maintenance and repairs of all your equipment on site is essential for safe working conditions. This is also covered under the LOLER regulations.   

Supervision - you must have appropriately trained supervisors on-site at all times when your cranes are in operation. 

Limits - any employee working on your cranes must know your equipment's safe load capacity and lifting limits per your crane's load chart limit. Everyone must know the safe working load of your cranes. You might also consider using automatic safe load indicators to avoid mistakes.

Clear warnings - appropriate warning signs in all of the most dangerous areas of your site must be clearly posted for your employees to see. Your employees must also be told what these signs mean, so they can recognise when they are entering danger zones. 

Appropriate PPE (Personal Protective Equipment) - visibility and head, foot and eye protection are essential when operating cranes. Your risk assessment will inform you of the most appropriate protective equipment for your site, including hard hats or safety harnesses. 

Plan - safety plans are essential before any work is carried out on your site. Even before the cranes arrive, you should appoint someone to be in charge of pre-job safety planning. 

Ground conditions - the soil or surface your cranes will operate on must be safe and levelled where needed, including using spread mats on a scale of 1:3. 

Clearance - ensure that when your crane outriggers are fully extended, it is at least 1 metre clear of utility holes or trenches. 

Weather - naturally, you shouldn't be using cranes when there are high winds or low visibility due to rain. 

Barricades - when you've determined the swinging radius of your crane, only authorised personnel, such as your certified rigger with appropriate workwear, should be allowed in the area. 

Trained rigger - only your rigger should be able to signal your crane operators.

Tag lines - you need at least two tag lines to control load swinging. You should also source other appropriate lifting tools you'll need. 

Appropriate equipment - you must have a choker hitch, straight and basket when operating any crane. 

Horn - all of your cranes should have a reversing beep horn. 

Planning lifting operations

Planning is one of the most important parts of any project, but especially so with crane lifting operations and working with cranes. Planning can help you spot hazards prematurely and keep your employees safe.

Given how crucial planning is, you should ensure that those you appoint to plan your crane operations are appropriately trained with a practical and theoretical understanding of how these construction projects should be done. 

Your plan should detail how you will mitigate the hazards noted in your risk assessment, including any resources and procedures you'll need.

It must also establish who is responsible for overseeing that your crane lifting operations are carried out safely.

For more practical guidance about what is required in your plan, you can consult the British Standards BS 7121, Part1 of 2006, which establishes the acceptable standards for managing any lifting operation utilising cranes.

Safe systems of work

If you have created an effective plan, you should have a safe system of work for your employees to follow. You should record this system, so everyone working on the project understands their safety responsibilities. This record is commonly known as your 'method statement' or 'lifting permit'. 

1. Preparation, including site preparation, crane erection and dismantling.
2. Choosing and sourcing appropriate crane safety and work equipment.
3. Having safe signalling and slinging systems in place.
4. Inspection and maintenance schedules for your cranes and equipment.
5. Inspection and maintenance schedules for your cranes and equipment.
6. Hiring adequately trained personnel.
7. How your trained personnel will supervise your crane lifting operations.
8. Preventions for unsafe or unauthorised movement or use of cranes. 
9. Safety and control measures for crane operators.
10. Thorough examinations and safety reports.

Supervision of lifting

You must ensure there is an appropriate level of supervision of lifting by a competent person during your project. This supervision should reflect your projected risks and the number of personnel working on your operations.

Your crane supervisor will ensure any crane lifting operations are carried out per your method statement, meaning you need to hire a supervisor will the experience and knowledge to do so.

You must also give them all the authority required to judge developing hazards and to stop the project if they deem it unsafe. 

Thorough examination

If you are hiring your lifting equipment, the crane hirer company will conduct their own examinations. Still, it is on you as the crane operator to ensure the examinations and required reports are sufficient for safety standards.

Any records or reports of examinations must be available in writing and stored safely for view by enforcing authorities. Valid inspection certificates should also be readily available.