Crane Hazards
Crane Hazards
Crane Hazards
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.
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.
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.
Common
Overhead Crane
Hazards And
Their Prevention
By TNT CranesJune 8, 2017No Comments
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.
4 min read
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.
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.
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.
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.