Working with cranes can be dangerous, but overcoming safety risks is possible with proper procedures. Teams must understand relevant compliance requirements and best practices to support the efficient, secure operation that is safer for people and property.
We explore the most common crane operation risks and what you can do to comply with the relevant regulations below.
6 Common Crane Safety Risks and Violations
Learn more about the common safety and crane compliance challenges.
1. Limited Visibility
There are a few reasons why crane operators may experience limited visibility on the job:
- Moving large and complex loads at significant heights
- Varying weather conditions
- Working at night with imperfect lighting
- Obstacles on the worksite
These situations can make detecting nearby hazards more challenging, posing unique safety and compliance risks. A signalperson often works with crane operators to help them navigate the worksite with an extra pair of eyes and ears.
The signalperson actively communicates through hand or verbal signals to direct the operator's movement and support greater accuracy. If there are unsafe working conditions, such as unstable ground or an obstruction in the path of travel, the signalperson has the authority to halt operations until the worksite is secure.
2. Improper Load Handling and Stabilization
Crane tip-overs happen because workers use the wrong crane type, exceed the crane's load limits, or improperly set up the outrigger, which stabilizes the crane. Overloading the crane can also lead to tipping or collapsing.
To avoid such accidents, encourage your workers to:
- Refer to the load chart for the crane's load capacity.
- Secure the load with slings.
- Use sufficient counterweights.
- Set up the outrigger based on the manufacturer's guidelines.
Everyone working with and around the crane must recognize signs of instability. They must be vigilant and watch for sudden movements, shaking, or vibrations. When these signs appear, follow emergency protocol immediately. Evacuate the area is needed to protect everyone’s safety.
3. Adverse Weather Conditions
Extreme weather conditions can make moving forward with crane operations unsafe. For instance, strong winds can tip the machine over and injure nearby workers. Heavy rain can impact visibility and ground stability. Lightning is especially dangerous — it can pose a risk to the operator, result in electrical damage, and pose a shock hazard.
The crane manufacturer should have guidelines on the wind speeds the equipment can handle, while you should halt operations during other unfavorable weather conditions.
Remember that for a crane operation to be safe, the ground should be firm, drained, properly graded, and meet the manufacturer's level specifications.
4. Inadequate Site Protection
Worksites involving heavy equipment can quickly become dangerous. Taking steps to avoid accidents and promote safety is crucial for minimizing risks. About 79 out of 154 fatal crane injuries involve a worker being hit by a falling object from the crane.
Although wearing complete personal protective equipment (PPE) can help improve workers' safety, teams must take additional safety precautions. To reduce the chances of crane-related accidents, employees should:
- Put proper safety devices in place, such as warning alarms.
- Guard moving parts to protect workers from belts, shafts, gears, and pulleys.
- Avoid working under the boom.
- Set up barriers and netting to catch falling objects.
Crane operators should also keep a safe distance from nearby power lines and use independent insulated barriers to avoid electrocution. Your business should communicate with the local power line owners to de-energize and ground the lines. If a crane's parts contact an active power line, workers risk electrocution.
Teams must be aware of relevant Occupational Safety and Health Administration (OSHA) and American Society of Mechanical Engineers (ANSI/ASME) guidelines. OSHA standards 29 CFR 1926.1407 and 1926.1408, along with ANSI/ASME B30.5, provide guidelines for minimum clearance distances between cranes and power lines based on the power line's voltage.
5. Lack of Training and Certifications
Without proper training and certification, workers cannot do their jobs efficiently and safely. Your crane operator understands operational best practices.
The required certification depends on the type and capacity of the crane. OSHA requires those working with cranes, including operators, riggers, inspectors, and signalpersons, to meet minimum training and certification requirements.
6. Irregular Inspection and Maintenance
Failure to inspect a crane regularly can lead to accidents and increase the chances of the machine's breakdown. The competent person in charge of inspection should identify potential hazards and suggest corrective actions.
A qualified person must perform inspections. These checks include:
- Frequent inspections: Daily or pre-shift examinations of the control system, braking system, load-sustaining structural components, and power sources to ensure proper function.
- Periodic inspections: More in-depth inspections (monthly to annually) to evaluate wear and tear, with the frequency depending on usage, environment, and manufacturer recommendations.
Create a maintenance checklist based on your specific equipment and site conditions. The crane operator should not use any crane that shows signs of a mechanical or electrical malfunction. Remember to record all inspections, maintenance, and repairs for easier reference during regulatory review.
Relevant Standards to Remain Safe and Compliant
There are multiple mandatory crane safety regulations you must follow, outlined by OSHA. Your team should also be well-versed in local and state laws relating to safe crane operation.
In addition to OSHA standards, your business may follow recommendations from other regulatory bodies to support maximum safety on the worksite. These include:
- International Organization for Standardization (ISO)
- Crane Manufacturers Association of America (CMAA)
- American Society of Mechanical Engineers (ASME)
Your equipment manufacturer’s operations manual also includes guidelines for safer, more secure procedures.
What Happens if You Fail to Comply?
Failure to adhere to safety standards can result in significant repercussions:
- Accidents: Noncompliance significantly increases the risk of accidents, potentially leading to fatal or life-altering injuries for workers.
- Operational downtime: Inadequate maintenance and repairs can cause equipment failure, delaying project completion. Accidents also trigger investigations that can halt operations for extended periods.
- Legal and financial implications: Violations of safety standards can result in substantial fines, penalties, and even imprisonment. The OSHA Act of 1970, for example, stipulates significant fines and potential imprisonment for willful violations.
- Damaged business reputation: Accidents and safety lapses can severely damage a company's reputation, eroding trust with clients or employees, and negatively impacting future business prospects.
Simplify Compliance With Crane Inspection by CICB
There are many crane compliance risks to be mindful of, and managing them on your own can be challenging. CICB is here to make compliance simple.
We have over 50 years of experience in the field. We offer the most thorough safety and compliance assessments with all relevant standards from regulatory bodies like OSHA, ASME, ANSI, and CMAA. Our experts can inspect your crane, helping your business extend equipment lifespans and reduce maintenance costs while maintaining safety.
Are you ready to get started? Learn more about the crane inspections by CICB today.
