Crane Safety Toolbox Talk - Safety Checklist & Resources

Cranes Are Often The Most Powerful Equipment On The Job

Cranes are among the most powerful and essential machines on construction sites. Their ability to lift and move massive loads makes them indispensable, but it also brings significant risks if not handled properly. These large, complex machines require strict adherence to safety protocols to protect workers, bystanders, and nearby structures.

According to the Bureau of Labor Statistics (BLS) and OSHA, approximately 40 construction workers lose their lives each year due to crane-related accidents. As a result, cranes weighing more than 2,000 pounds are subject to strict regulations. Operators must be certified by the National Commission for the Certification of Crane Operators (NCCCO). Companies that operate cranes are legally responsible for any damage or harm caused, which is why many invest in specialized insurance coverage.

Crane Safety Toolbox Talk

Checklist of critical items to monitor before moving a load

1. Inspect the area for overhead obstructions such as power lines, trees, or buildings.
2. Confirm that all lifting equipment—slings, chains, and straps—is rated for the weight of the load and clearly marked with its safe working limit.
3. Identify and mark potential pinch and crush points around the crane and the landing area using paint or chalk to ensure visibility.
4. Set up barriers around the crane’s swing radius to prevent unauthorized access during operations.
5. Ensure the load is balanced and free from obstacles in its path.
6. Develop and share a detailed lift plan with all relevant personnel. Any changes to the plan must be communicated immediately.

Checklist of critical items to monitor while moving a load

1. Never allow anyone to stand or work under a suspended load.
2. Keep all personnel at a safe distance from the crane during lifting, moving, or lowering.
3. Crane operators must remain focused and avoid distractions like phone calls or texting.
4. A trained signal person is required. They must use standard hand signals and maintain clear communication with the operator.
5. Only one person should control the lift or give signals at a time unless the situation requires multiple people due to hazards.
6. Use an air horn to alert everyone when a lift is in progress. This helps draw attention even to those not directly watching the crane.
7. Avoid raising the load higher than necessary to reduce risk.
8. Never leave a load hanging in the air unattended.

Toolbox Talk Outline

• Review the task at hand and confirm everyone understands their role.
• Go over the pre-lift and during-lift checklists.
• Discuss environmental hazards, PPE usage, first aid procedures, and emergency response plans.
• Allow time for questions and feedback from the crew.
• Consider a short quiz to ensure everyone is familiar with the safety guidelines.

Safety Equipment - Signs, Air Horns & Lights

Safety Signs and Stickers

Safety signs and stickers are crucial for communicating risks on a job site. OSHA and ANSI provide guidelines for visual warnings used on cranes. Common materials include vinyl, polyester, aluminum, and plastic. Many suppliers, like SafetySign.com and Amazon, offer a variety of options. In areas with multiple languages, bilingual signs can improve clarity and safety.

Air Horns and Audible Signals

Before and after each lift, use an air horn or audible alarm to alert nearby workers. Different signals can be used to indicate “start,” “all clear,” and “finish.” These alerts help ensure that even those not directly watching the crane are aware of ongoing operations.

Safety Lights

Proper lighting is essential for visibility, especially in low-light conditions or bad weather. Warning lights and spotlights around the crane help identify its location and reduce the risk of accidents. Lighting ensures that the crane stands out against its surroundings, making it easier for workers to stay safe.

Transportation of Cranes

Transporting cranes requires careful planning, especially in urban or industrial environments. Before moving, study the route, measure dimensions, and account for extra space around turns. Spotters are often needed to guide the crane through tight spaces. Always follow local laws regarding oversized loads, including warning flags, signs, and possible police escorts.

Be mindful of weight limits on bridges and roads. Some cranes may exceed these limits, so checking the route in advance is essential to avoid delays or damage.

Lift Plan

A lift plan is similar to an architectural blueprint—it outlines every detail to ensure a safe and successful operation. It includes the load's weight, the crane's lifting capacity, center of gravity, dimensions, and lifting points. It also covers rigging requirements, height restrictions, and risk mitigation strategies.

Once created, the lift plan must be shared with all involved parties. Since plans can change, it’s important to update and distribute the latest version to everyone to avoid confusion.

OSHA Crane Safety Hand Signals

Clear communication between the crane operator and signal person is vital. OSHA has established standardized hand signals to ensure consistency across the industry. Below are some of the most commonly used signals.

Stop
Arm extended horizontally to the side, palm down, arm swung back and forth.

Emergency Stop
Both arms extended horizontally to the side, palms down, arms swung back and forth.

Hoist
Upper arm extended to the side, forearm and index finger pointing straight up, hand and finger make small circles.

Raise Boom
Arm extended horizontally to the side, thumb up, other fingers closed.

Swing
Arm extended horizontally, index finger points in direction of swing.

Retract Telescoping Boom
Hands at waist level, thumbs pointing at each other, other fingers closed.

Raise the Boom and Lower the Load
Arm extended horizontally to the side, thumb up, fingers open and close while load movement is desired.

Dog Everything
Hands held together at waist level.

Lower
Arm and index finger pointing down, hand and finger make small circles.

Lower Boom
Arm extended horizontally to the side, thumb down, other fingers closed.

Extend Telescoping Boom
Hands at waist level, thumbs pointing outward, other fingers closed.

Travel/Tower Travel
Fingers up, arm extended horizontally out and back to push in the direction of travel.

Lower the Boom and Raise the Load
Arm extended horizontally to the side, thumb down, fingers open and close while load movement is desired.

Move Slowly
One hand placed in front of the action signal hand.

Use Auxiliary Hoist
Arm bent at elbow, forearm vertical, tapped with other hand. Then regular signal is used to indicate action.

Crawler Crane Travel, Both Tracks
Rotate fists around each other in front of body; rotation away from body indicates forward; toward body indicates backward.

Use Main Hoist
Tap top of head with one hand, then give regular signal to indicate action.

Crawler Crane Travel, One Track
Raise fist on the side of the track to be locked. Rotate other fist in direction of travel.

Trolley Travel
Palm up, fingers closed, thumb pointing in direction of motion, hand jerked horizontally in that direction.

Source: Full OSHA Crane Guidelines

Crane Rental

When renting a crane, many companies offer valuable resources, including certified operators, transportation services, and assistance with lift planning. It's always wise to consult with your rental provider early in the process to ensure you have everything you need for a safe and efficient operation.

Resources

12 types of cranes
OSHA Crane, Derrick and Hoist Safety
Crane safety video

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