OVERHEAD CRANE SAFETY—THREE MAJOR

HAZARDS AND PREVENTATIVE MEASURES

Countless companies in the manufacturing and construction industries rely on overhead cranes to lift
and transport materials. When installed and used properly, these systems make operations easier
and safer. But, overhead crane accidents cause severe injuries and fatalities every year. Preventing
these disasters requires workers to recognize certain hazards that occur during operation and follow
safety procedures to avoid them.
There are multiple hazards that can arise regarding cranes in general. Many accidents involve large
lift systems like tower cranes and mobile cranes. But hazards do exist with all types of cranes—
including overhead cranes—and in all facets of crane operation. (Overhead cranes are defined
by OSHA 1910.179(a)(8) as a crane with a movable bridge carrying a movable or fixed hoisting
mechanism, and traveling on an overhead fixed runway structure.) Analysis of overhead crane accidents
reveals three common safety hazards that every company using overhead lift systems should be aware of to keep
their workers safe. It’s important to be familiar with these hazards and learn to recognize them in the workplace in
order to avoid them. The three most common hazards involving overhead cranes include electrical hazards,
overloading, and materials falling/slipping from overhead hoists. The following analysis of each hazard provides a
description, potential risks, reasons why accidents occur, preventative measures to avoid them, and applicable OSHA
requirements. One commonality that all three hazards share is the qualifications of crane operators. It is the
responsibility of the crane owner and job supervisor to ensure that crane operators are competent and qualified to do
the job. Click here to read more about training requirements and minimum competent personnel guidelines outlined by
OSHA.

ELECTRICAL HAZARDS
According to OSHA, nearly 50 percent of overhead crane accidents are the result of machinery
coming into contact with a power source during operation. Power line contact is literally defined as
the inadvertent contact of any metal part of a crane with a high-voltage power line. Power line
contact most often occurs when the crane is moving materials nearby or under energized power
lines and the hoist line or boom touches one of them. Usually, the person who is electrocuted is
touching the crane when it comes into contact with the power line. But, the danger is not just limited
to the operator. It extends to all personnel in the vicinity.
A single contact with power lines can result in multiple deaths and injuries. Each year nearly 200
people die from power line contact and about three times as many are seriously injured. Most victims
are guiding the load at the time of contact, but risks extend to everyone present at a job site.
Power line contacts most often occur because safety planning isn’t considered and preventative
measures haven’t been taken to avoid hazards. Planning is one of the biggest accident deterrents
available. To start, it’s important to establish who is in charge of prejob safety planning before any
cranes arrive at a worksite. Furthermore, cranes should be kept away from unsafe working areas;
OSHA and ANSI both outline safe distances operators must maintain from a power source when
working at a job site. Areas that are considered hazardous are referred to as danger zones, and
crane operators should be clearly notified of all potential danger zones. The area within a 10-foot
radius of a power line is considered an unsafe work area—or danger zone—and it must be clearly
marked on the ground by insulated barriers, fences, tape, etc. This will help create visual clues for
workers to ensure that the crane is always positioned so that the boom and hoist line can’t intrude in
the danger zone.
OSHA also regulates that overhead crane operators use precautions when working near power
lines—even outside of the 10-foot radius. This means, operators should consider all power lines as
energized until the electric company tells him or her otherwise. Operators should also maintain a
safe speed when operating near power lines. Crane booms or truck-mounted trolleys using an
electrical remote control system for loading and unloading can also be very dangerous. If the boom
contacts a power line, the operator holding the control box is usually electrocuted instantly. This type
 OVERHEAD CRANE SAFETY—THREE MAJOR
HAZARDS AND PREVENTATIVE MEASURES
of equipment should never be used near power lines. A non-conductive, pneumatic or radio remote
control system is a much safer choice when working near power lines.
Overall, it’s important for operators and workers to receive the appropriate training to avoid danger
zones where electrocution can occur. Operators should have workers observing nearby to assist
them whenever it is difficult to visually maintain the necessary clearance. Be sure that any ladders,
tools, and systems are non-conductive, and ask the electric company to de-energize and ground
power lines or install insulation whenever people are working near them.

 29 CFR 1910.333(c)(3)—Selection and use of work practices—Working on or near exposed

energized parts—Overhead lines
 29 CFR 1926.550(a)(15)—Cranes and derricks—General requirements—Electrical
distribution and transmission lines

OVERLOADING
According to OSHA, 80 percent of all crane upsets and structural failures can be attributed to
exceeding the crane’s operational capacity. When a crane is overloaded, it is subject to structural
stresses that may cause irreversible damage. Swinging or sudden dropping of the load, using
defective components, hoisting a load beyond capacity, dragging a load and side-loading a boom
can all cause overloading.
OSHA estimates that one crane upset occurs for every 10,000 hours of crane use. Nearly 80 percent
of these upsets can be attributed to predictable human error when the operator inadvertently
exceeds the crane’s lifting capacity. Overloading most often occurs when poorly trained personnel
are allowed to operate cranes. Oftentimes, operators mistakenly believe they are able to rely on their
instinct or experience to determine whether a load is too heavy. It’s crucial that any crane operator
know the weight of a load and the capacity of the crane. Using technologies such as load-measuring
systems for training and planning can greatly reduce the hazard of overloading and operator
incompetency.
OSHA requires workers to provide formal training for all crane operators, but operator certification is
only required for operators using equipment with a maximum manufacturer-rated capacity of 2,000
pounds or less. Employees who are not qualified are only permitted to operate equipment as
operators-in-training with a certified trainer. Formal training should ensure a working knowledge of
crane load charts, and on-the-job training is a great preventative measure if the trainer is qualified.
Overall, most crane safety programs outline competent personnel requirements, and it’s a good idea
to become familiar with them. Cranes have become more sophisticated, with the ability to lift heavier
loads further and faster than ever before. Today’s operator must be well trained and have a clear
understanding of load dynamics, lifting capacities at various configurations, and the conditions under
which such lifting capacities are valid.

 29 CFR 1910.179(g)(5)(iv)—Overhead and Gantry Cranes—Switches

 29 CFR 1910.179(n)(4)(I)—Overhead and Gantry Cranes—Handling the load—Hoist limit
switch
 29 CFR 1910.179(a)(50)—Overhead and Gantry Cranes—Rated Load
 29 CFR 1910.179(b)(8)—Overhead and Gantry Cranes—Designated Personnel
 29 CFR 1910.179(a)(35)—Overhead and Gantry Cranes—Designated Employee
 29 CFR 1926.550(g)(3)(ii)(C)—Cranes and Derricks—Instruments and Components
 29 CFR 1926.21(b)—Safety Training and Education
 OVERHEAD CRANE SAFETY—THREE MAJOR
HAZARDS AND PREVENTATIVE MEASURES
MATERIALS FALLING

Falling materials is a major concern at any work place or job site using overhead cranes. Visual
impairment, two-blocking, slipping, mechanical failure, or operator incompetency can all result in
serious injuries or fatalities. If materials are not properly secured, for instance, the load can slip and
land on workers in the vicinity or cause major damage to property. For larger or mobile cranes,
undesired movement of material can pinch or crush workers involved in the rigging process.
Statistics show that nearly 20 people died in 2012 as a result of accidents with overhead hoists.
That’s because the loads being lifted by overhead hoists tend to be fairly heavy and cause serious
damage if dropped. Slings and attachments that aren’t secured properly can be a major safety
hazard, and when objects begin to slip, they will eventually crash to the floor below.
One way to reduce the risk of falling materials is to perform regular maintenance of hoists. Load
testing maintenance ensures that you know how many pounds the hoist can handle, and it helps to
maintain good working condition. Maintenance should always be treated seriously when it comes to
heavy machinery. If a moving part on an overhead crane wears out or breaks the hoist, it can cause
serious damage. Performing regular maintenance ensures the hoist and overhead crane remain in
good working order and that all operations run smoothly.
Aside from maintenance, improper securing of the load or the slings that carry the load is one of the
leading causes of accidents with overhead hoists and cranes. If the load or sling holding the load
isn’t properly secured, the objects can slip out, tip, and eventually crash to the ground below.
Mechanical failure can also cause machinery to malfunction unexpectedly and drop a heavy load. To
reduce the risk, OSHA mandates that operators make daily crane inspections. When mechanical
problems do arise, operators should use the lockout/tagout procedure to prevent accidental startup
or movement of the crane until the problem has been repaired.
Employees working around overhead cranes should always wear proper head, foot, hand, and eye
protection. The crane operator and any workers below should also be aware of his/her surroundings
and never walk under a lift. A crane operator must always lower a load to the ground before leaving
the lift or during idle times. When moving items, he or she should never raise the load higher than
required for clearance.
When operating a hoist, properly trained employees in the vicinity should understand that they are
working in a dangerous area. Installing “Hoist Danger” signs around the work area will help to alert
employees that a hoist is operating over their heads. Workers should be trained to stay clear of the
hoist, and they should never walk beneath loads suspended in the air. Likewise, suspended loads
should never be moved over employees and personnel should never be lifted or transported on a
hoist.
Careful operation of the hoist is another important safety factor to consider whenever overhead
cranes are used. The person responsible for managing the hoist should be well trained and qualified.
Moving the crane too quickly and jerking the hoist when it’s bearing a heavy load can be hazardous
to the crane operator and workers nearby. Changing or reversing direction should be done slowly
and carefully. Reversing direction can cause heavy loads to spill, and swinging the load is very risky.
Operators and controllers must maintain 100 percent focus on the task at hand to avoid potentially
dangerous situations.

 29 CFR 1926.550(d)(3)—Cranes and Derricks—Overhead and Gantry Cranes

 29 CFR 1910.179—Overhead and Gantry Cranes—Holding Brakes and Control Braking
 29 CFR 1910.179(e)(6)(i)—Exposed Moving Parts
 OVERHEAD CRANE SAFETY—THREE MAJOR
HAZARDS AND PREVENTATIVE MEASURES
 29 CFR 1910.179(f)(1)(ii) —Overspeeding
 29 CFR 1910.179(b)(8)—Overhead and Gantry Cranes—Designated Personnel
 29 CFR 1910.179(b)(6)—Overhead and Gantry Cranes—Clearance from Obstruction
 29 CFR 1910.179(a)(42)—Overhead and Gantry Cranes—Hoists
 OVERHEAD CRANE SAFETY—THREE MAJOR
HAZARDS AND PREVENTATIVE MEASURES

Common
Overhead Crane
Hazards And
Their Prevention
By TNT CranesJune 8, 2017No Comments

Some Common Overhead Crane

Hazards and Tips On How to Prevent
Them
Preventing Overhead Crane Hazards: In any type of industry, the coming together of
anticipation and pro-actively handling problems is something, which does result in greater
success than just reactively responding to incidents. If an individual works in the world of
construction and manufacturing, there are hazards always present at job sites, but with proper
training and preparation ahead for them, a lot of issues can be prevented.
In order to keep all those involved safe, all operators and workers need to understand the most
basic of all safety hazards, and how to recognize any of them right away. Please read on to learn
more about the many potential risks that are a part of overhead cranes and the accompanying
preventable measures.

Potential Electrical Hazards

 OVERHEAD CRANE SAFETY—THREE MAJOR
HAZARDS AND PREVENTATIVE MEASURES
About 50% of all crane accidents that happen overhead can be attributed to machinery coming
into contact with a power source of some kind during operation. Typically, why this occurs is
because, as a crane moves materials close to or beneath energized power lines, the hoist line or
boom gets into contact with the electrical source. This is an issue, which is about half of all
hazards that are associated with these overhead cranes, and it can be stopped with good safety
planning.
Safety planning that is effective can be done before the cranes even get to the worksite. It is
important to establish who will be in charge of any and all pre-job safety. Every danger zone
should be clearly marked, and this does specifically apply to, the 10-foot radius of all power lines
of the entire area. The whole area should be considered to be an unsafe working place from the
get go. The 10-foot radius can be marked with barriers, fences, taping, etc. to give clear visual
clues for all workers.
In addition to this, make sure to ask electrical companies to de-energize or to ground any existing
power lines when there are individuals working in close proximity to them. However, until
specifically informed by the electrical company, all operators should assume that all power lines
are energized and extremely dangerous. A final preventative measure is to make sure all ladders,
tools, and other systems being used on the work site aren’t at all conductive.

Crane Overloading
When a crane exceeds over its operational capacity, it can also prove to be the very thing, which
tends to cause about 80% of all crane accidents and structural failures as well. The overloading
of the crane’s operational capacity is caused by some of the following:
 The presence of swinging or a sudden dropping of any load
 Any defective components
 The hoisting of a load that is beyond its normal capacity
 The dragging of a load
 Whenever side-loading a boom
A lot of these mistakes are the result of predictable human error. The formal training for
operators should have a working knowledge of some key points, and any conditions where stated
lifting capacities happen to be valid. Some of these key points are crane load charts and lifting
capacities. Operators shouldn’t just rely on instinct or experience to decide if weight load is
correct.

Any Materials Falling

One of the best ways to lessen the chance of any materials falling down from cranes is clear. It is
to make sure to perform regular maintenance of hoists. An example of this is to do load testing
maintenance to ensure that you know how many pounds a hoist can handle exactly. It also will
provide an accurate indication of just how well the hoist is functioning currently. Another way to
reduce the chance of mechanical failure is by performing inspections of the crane each day. If,
and when, a potential problem is identified by the operators, they need to make sure
to implement the lockout/tag-out procedure.
 OVERHEAD CRANE SAFETY—THREE MAJOR
HAZARDS AND PREVENTATIVE MEASURES
Though it may be obvious, what should be clearly stated is this, that workers need to always
wear the proper head, foot, hand, and eye protection while working on the job site itself. They
also need to be constantly aware of what is going on in their surroundings. They don’t want to
accidentally go walking beneath a suspended load at any time.
Here at TNT Crane Service, Inc., we always make sure to put safety and prevention first. It is
our number one priority. Because of this fact, we ensure that all the machines we have are kept
well maintained and up to date. What this does is ensures that you will be getting the most
effective, as well as, the most reliable equipment that is available. Please view the equipment that
we have on hand for sale or rental today. It may help you to find the crane that you require for
your next major project coming up.
 OVERHEAD CRANE SAFETY—THREE MAJOR
HAZARDS AND PREVENTATIVE MEASURES

Crane Safety Hazards and

Control Measures
Katie Martinelli

April 23, 2018

4 min read

Since 2001, accidents involving tower cranes have resulted in 25 serious

injuries and 9 fatalities. This highlights that, if you use cranes and other
lifting equipment at work, being aware of the hazards and knowing what steps
you can take to reduce your risk is crucial to ensuring your safety.

This article will detail the main crane-related hazards you might encounter at
work and will provide you with some important safety tips to protect yourself from
injury.

What are the Most Common Crane Hazards?

Working with cranes poses many hazards, and unsafe working practices can
result in injuries, fatalities and costly damage to buildings and materials.
Therefore, it’s important you’re aware of the main hazards and how you can
avoid them.
 OVERHEAD CRANE SAFETY—THREE MAJOR
HAZARDS AND PREVENTATIVE MEASURES

Some of the main crane-related hazards include:

Falling Loads

When working with overhead cranes, falling loads are one of the most common,
and most dangerous, hazards. A falling load can result in several injuries,
fatalities and significant structural damage to buildings and property. Additionally,
it will also lead to significant time and money costs.

Falling loads from an overhead crane could be the result of:

 Operator incompetency. You must ensure your employees are

adequately trained so they are able to carry out their roles competently and
safely.
 Slipping. If you don’t secure loads properly it can result in slipping
material.
 Mechanical failure. The risk of mechanical failure can be reduced if you
ensure a competent person carries out routine inspections, maintenance
and repairs at suitable intervals.
 Two blocking. Two blocking occurs when an uppermost hoist line
component (i.e the load block, hook block, overhaul ball) touches the
upper block, boom tip or similar component. When two blocking occurs,
increased tension is placed on the line which can result in falling loads or
crane components.
 OVERHEAD CRANE SAFETY—THREE MAJOR
HAZARDS AND PREVENTATIVE MEASURES

Electrical Hazards

Around 50% of accidents involving overhead cranes are a result of a metal part
of a crane coming into contact with a power source (i.e a high-voltage power
line). There’s a risk of a crane’s hoist line or boom touching energized power
lines when moving materials nearby or underneath. While those directly touching
the crane are the most likely to be electrocuted, any workers in the vicinity are
also at risk. Therefore, one accident can result in multiple deaths and
injuries. Around 200 fatalities per year are the result of contact with power lines,
so it’s crucial that pre-job planning is carried out prior to starting work.

Crane Overload

The majority of crane structural failures and upsets are the result of somebody
overloading a crane. If you exceed a crane’s operational capacity, you are likely
to subject it to structural stresses and cause irreversible damage.

You could overload a crane if you:

 Swing or suddenly drop loads.

 Hoist loads beyond the cranes capacity.
 Use defective components.
 Drag loads.
 Side-load a boom.
 OVERHEAD CRANE SAFETY—THREE MAJOR
HAZARDS AND PREVENTATIVE MEASURES

Crane Safety Tips

When working with cranes, there will always be hazards. However, you can
minimise the risks by ensuring you take appropriate precautions to undertake all
operations safely.

To carry out your crane operations safely, you should:

 Appropriately train all employees. As an employer, you have a legal

responsibility to provide appropriate health and safety training to all your
employees so they’re competent at their jobs. By training your employees
you’ll increase workplace safety, satisfaction and profits as you reduce
injuries, fatalities, accidents and sickness absence.
 Ensure employees know they must not stand under loads and ensure
operators never lift a load over an employee. You must never stand
under a crane or have a load lifted over you. It’s crucial your employees
are aware of this and avoid walking through any zones where cranes are
overhead.
 Know, understand and comply with the Lifting Operations and Lifting
Equipment Regulations 1998 (LOLER). To find out more about your
legal responsibilities under LOLER, have a look at our LOLER FAQ
Guide.
 Carry out routine maintenance and repairs of all on-site equipment at
appropriate intervals. Part of your legal responsibility under LOLER
involves carrying out routine, periodic maintenance and repairs to ensure
your machinery is in safe working condition.
 Ensure a supervisor is present on site at all times when cranes are in
operation.
 Make employees aware of, and strictly enforce, your load and lifting
limits.
 Ensure clear warning signals are displayed on-site when needed. You
must display the relevant hazard signs in all danger zones on-site to warn
your employees of the potential hazards. You must also ensure all your
employees know and understand all the warning signs so they are aware
of when they are entering a danger zone.
 OVERHEAD CRANE SAFETY—THREE MAJOR
HAZARDS AND PREVENTATIVE MEASURES

 Select appropriate PPE for all employees. You must ensure your
employees wear appropriate foot, head and eye protection, along with any
other PPE you have identified in your risk assessment.
 Properly safety-plan all jobs before starting work. You must also
decide who’s in charge of pre-job safety planning prior to any cranes
arriving on-site.

For more information about complying with LOLER regulations and carrying out
your LOLER inspections, have a look at our LOLER Inspection
Checklist article.