Overhead Crane Safety—Three Major Hazards and Preventative Measures

Overhead cranes are an effective way to lift, move, and transport goods and materials. Many sectors, such as construction, manufacturing, and the metal industries, use them to complete their daily operations.

There are many safety concerns when loading, unloading, and moving heavy materials. Accidents can occur at any time due to various reasons. Poorly maintained equipment and lack of training increase the hazards within work zones.

Prioritizing overhead hoist safety can minimize risks and increase the safety of workers. Take a look at the three major hazards and preventive measures to improve overhead crane safety. 

Are Cranes Dangerous?

There is an increased risk when working near cranes. Overhead cranes generally transport or move heavy material, equipment, and machinery. The crane itself consists of heavy and hazardous materials and components.  

The U.S. Bureau of Labor Statistics states that an average of 42 people were fatally wounded in crane accidents from 2011 to 2017, which amounts to 297 workers. Some workers, including crane operators and on-site workers, suffer various injuries that result in hospitalization. Cranes can also damage property and equipment. It results in costly repairs, liabilities, and financial losses. 

Three Major Crane Hazards and Preventative Measures

Here are the three major hazards and causes of using overhead cranes, as well as preventive measures to promote overhead crane safety.

Electrical Hazards

Many crane accidents happen when a crane comes into contact with an energized or live power line. Several workers get hurt or fatally injured from powerline contact each year.

High-voltage power lines can cause injuries such as burns, shocks, or fatalities. The crane boom or hoist line is at risk of hitting a power line when working in close proximity. This creates an electrical current that can injure the operator at the controls.

Here are some preventive measures for minimizing electrical hazards:

• Take all preventive measures promptly.
• Hold a meeting to inform everyone of the project and the hazards involved. 
• Keep the crane boom and equipment at a safe distance from power lines.
• Use non-conductive crane taglines to stabilize materials and minimize swaying. 
• Create boundaries with flags, tape, or markings to keep workers at a safe distance. 
• Determine the line’s voltage to establish a safe distance from the power lines.
• Have a spotter present to alert the operator or personnel if they are too close to the power lines. 
• Stay at least 20 feet from the power lines to create a safe work zone.
• Avoid using excessive speed when moving material.
• Avoid touching power lines even if they appear insulated or weather-protected. 
• Ask authorities if they can de-energize the power lines if you need to complete work near them. 

Overloading

Overloading is loading too much material on the hoist that exceeds the weight limit of the crane. An overloaded crane can carry heavy loads that can damage and crush property when it falls off. It can also wound and fatally injure employees who are below the load or in the work zone.

Overloading a crane can cause strain on the hoist when lifting heavy loads. It causes the crane to become unstable, topple over, and collapse. The heavy loads can also cause the crane to bend and break.

Faulty load sensors or poorly maintained equipment can provide incorrect weight readings. This can lead employees and the operator to overload the crane. High wind speeds can also make a load unstable, adding extra strain when blown against the load. Instead of lifting, there is a practice called dragging or side loading, which adds extra stress and damage to the hoist.

Here are some preventive measures to avoid overloading: 

• Identify and operate within the crane’s load capacity.
• Check crane loads and detect unsafe conditions with various prevention devices and sensors. This includes the crane load limiter, load moment indicator, and rated capacity indicator. 
• Test and maintain all overload prevention devices to prevent inaccurate readings. 
• Avoid operating a crane at wind speeds of 20 mph and higher.
• Avoid dragging and side-loading by lifting the load before transporting. 

Materials Falling

Materials falling from cranes is another major concern. This can injure or fatally wound employees who are below in the work zone. Objects of all sizes are hazardous when falling from elevated heights. The causes of material falling include things slipping and unsafely secured material. It also includes loads not correctly placed or balanced on the hoist or platform.

Materials falling from the hoist aren’t the only concern. Poorly maintained cranes can have damaged or broken parts due to corrosion or wear. It can fall on property and employees, damaging equipment, and injuring workers. 

Minimize falling materials with these preventive measures:

• All employees must wear safety gear, including hard hats, safety boots, eye protection glasses, work gloves, and high visibility apparel.
• Use barriers and signs around the crane to prevent anyone from walking under load.
• Do not stand directly under suspended loads.
• Secure all loads and equipment.
• Conduct regular inspections and maintenance on cranes and equipment.
• Ensures all materials are properly loaded.
• Keep a safe distance from the crane swing radius.

Overhead Crane Safety Training

Crane operator and grounds personnel training is one of the most vital overhead crane safety measures. It gives operators and employees the knowledge to identify hazards and follow the correct processes.  

According to OSHA guidelines, all crane operators must complete training and get their license (1926.1427(a)) before operating a crane. The only instance where an operator can use a crane without certification is in training (1926.1427(a)(1)).  

There are various crane safety training programs workers can complete. Employers must ensure a qualified person conducts the training. The reasons why training is vital for all employees include the following:

• They can recognize hazards before operating the crane.
• It minimizes the risk of accidents.
• It reduces the risk of injuries and fatalities.
• It teaches operators how to navigate the functions and controls.
• It teaches employees how to read charts. 

Preventive Measures Before Operating a Crane

There are a few preventive measures to set in place before using a crane. These apply to all operators and grounds personnel in the work zone:

• Check the weather to ensure you complete procedures in safe conditions.
• Inspect the crane, equipment, and devices to reduce damage and increase overhead hoist safety.
• A spotter, signal person, and competent personnel must be on-site to identify hazards.
• Use crane safety devices such as rail stops, crane brakes, etc.
• Set up barriers to prevent workers from entering the work zone. 
• Perform regular maintenance to preserve the integrity of the crane and equipment. 
• Crane operators, grounds personnel, spotters, and signal persons must know signals to communicate if they are out of earshot of one another. 
• Operators must lower suspended loads before moving away from controls. 

Contact Spanco for Reliable Crane Solutions

Spanco provides reliable and high-quality cranes that can help you complete your duties effectively and boost productivity. Our expert team of engineers and welders creates robust cranes using precision machinery to ensure you receive a product that can meet your loading needs.

We create cranes that meet OSHA and ANSI guidelines to increase the safety and durability of our equipment. We specialize in various products and cranes, including gantry cranes and jibs.

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