Crane Safety Toolbox Talk - Safety Checklist & Resources

Cranes Are Often The Most Powerful Equipment On The Job

Cranes are often the largest and most powerful machines on construction sites. Their incredible strength allows them to lift and move massive loads, but this power also comes with significant risks. These complex machines require strict adherence to safety protocols to protect workers, bystanders, and surrounding structures. Proper training, clear communication, and regular inspections are essential to prevent accidents and ensure safe operations.

According to data from the Bureau of Labor Statistics (BLS) and the Occupational Safety and Health Administration (OSHA), approximately 40 construction workers lose their lives each year due to crane-related incidents. To mitigate these risks, cranes weighing more than 2,000 pounds must be operated by certified personnel through the National Commission for the Certification of Crane Operators (NCCCO). Companies that use cranes are legally responsible for any injuries or damage caused, which is why many invest in specialized insurance coverage for crane operations.

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. Ensure that slings, chains, and straps meet or exceed the weight capacity of the load. All lifting gear should have tags indicating their safe working load.
3. Identify potential pinch and crush hazards around the crane and the load’s landing zone. Mark these areas clearly with paint or chalk for visibility.
4. Establish a safe perimeter around the crane using barriers or warning tape to prevent unauthorized access.
5. Confirm that the load is balanced and free of obstacles along its intended path.
6. Develop and distribute a detailed lift plan for all major lifts. Update and share any changes with the entire team.

Checklist of critical items to monitor while moving a load

1. Never allow anyone to stand or work beneath a suspended load.
2. Keep all personnel at a safe distance from the crane during lifting operations.
3. Crane operators must stay focused and avoid distractions like phone calls or texting while operating the machine.
4. A trained signal person must be present and use standardized hand signals. Both the operator and signal person must maintain visual contact at all times.
5. Only one person should give signals at a time unless there's an emergency situation requiring multiple people.
6. Use an air horn or siren to alert workers when a lift is in progress. This helps ensure everyone is aware of the crane’s movement.
7. Avoid raising the load higher than necessary to reduce the risk of accidents.
8. Never leave a load hanging in the air unattended.

Toolbox Talk Outline

• Begin by discussing the specific task at hand and its associated risks.
• Review the pre-lift and during-lift checklists to reinforce key safety steps.
• Address environmental hazards, personal protective equipment (PPE), first aid procedures, and emergency response plans.
• Encourage open discussion and allow team members to ask questions or provide feedback.
• Consider conducting a short quiz or test to confirm understanding of the safety guidelines.

Safety Equipment - Signs, Stickers, Air Horns & Lights

Safety Signs and Stickers

Visual signs and stickers are crucial tools for communicating safety information on a job site. OSHA and ANSI have established standards for crane signage to ensure clarity and effectiveness. Common materials include vinyl, polyester, aluminum, and plastic, which are durable and weather-resistant. Many suppliers, such as SafetySign.com and Amazon, offer a wide range of crane-specific signs and labels.

In areas where multiple languages are spoken, consider using bilingual signs to improve comprehension and safety awareness among all workers.

Sample Safety Signs

Source: SafetySign.com
Note: Equipment Radar is not affiliated with or sponsored by SafetySign.com.

Air Horns and Audible Alarms

Before starting a lift, use an air horn or audible alarm to notify nearby workers and clear the area. After the lift is complete, signal "all clear" to inform everyone that it's safe to return. Different horn patterns can be used for different stages of the lift, such as “start,” “all clear,” and “finish.”

These signals are especially important because not everyone may have a direct line of sight to the crane. They help increase situational awareness and reduce the risk of accidents.

Safety Lights

Proper lighting is essential for crane operations, especially in low-light conditions or when visibility is limited. Warning lights and spotlights can be installed around the crane to make it more visible to workers and nearby traffic. This helps prevent collisions and improves overall site safety.

Transportation

Moving a large crane to a job site requires careful planning, especially in urban or industrial environments. It’s important to map out the route in advance and measure all dimensions to ensure the crane can pass safely. Allow extra space for turns and tight corners.

Having spotters on either side of the crane can help guide it through narrow spaces. The driver and spotters must maintain constant communication—either visually or through radios.

If the crane is oversized, it may require special permits, flags, or even police escorts. Check local regulations regarding weight limits, especially if the route includes bridges or elevated roads.

Lift Plan

A lift plan is a detailed document that outlines how a heavy load will be moved safely. Similar to architectural blueprints, it requires precise planning and engineering expertise. A good lift plan includes:

• Load weight and crane lifting capacity
• Center of gravity location
• Maximum dimensions of the load
• Approved lifting points and rigging equipment
• Obstacles and height restrictions
• Risk assessment and mitigation strategies
• Detailed procedure, cost estimates, and site impact analysis

Once created, the lift plan should be shared with all involved parties. Any changes must be communicated promptly to ensure everyone is on the same page.

OSHA Crane Safety Hand Signals

Clear communication between the crane operator and signal person is vital for safe operations. OSHA has established standard hand signals that must be followed. Below are some of the most commonly used signals:

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

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

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

Raise Boom
With arm extended horizontally to the side, thumb points up with other fingers closed.

Swing
With arm extended horizontally, index finger points in direction that boom is to swing.

Retract Telescoping Boom
With hands to the front at waist level, thumbs point at each other with other fingers closed.

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

Dog Everything
Hands held together at waist level.

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

Lower Boom
With arm extended horizontally to the side, thumb points down with other fingers closed.

Extend Telescoping Boom
With hands to the front at waist level, thumbs point outward with other fingers closed.

Travel/Tower Travel
With all fingers pointing up, arm is extended horizontally out and back to make a pushing motion in the direction of travel.

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

Move Slowly
A hand is placed in front of the hand that is giving the action signal.

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

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

Use Main Hoist
A hand taps on top of the head. Then regular signal is given to indicate desired action.

Crawler Crane Travel, One Track
Indicate track to be locked by raising fist on that side. Rotate other fist in front of body in direction that other track is to travel.

Trolley Travel
With palm up, fingers closed and thumb pointing in direction of motion, hand is jerked horizontally in direction trolley is to travel.

Source: Full OSHA Crane Guidelines

Crane Rental

When renting a crane, many companies offer a variety of services, including safety resources, certified operators, and transportation support. Some rental providers can also assist with creating a lift plan or refer you to a qualified engineer. Since every project is unique, it's always a good idea to consult with your rental company early in the planning process to ensure everything is set up correctly and safely.

Resources

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

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