Crane Lifting Hazards in Construction: Safety Measures to Prevent Accidents

Crane is very popular construction machines that can lift up to 30 tons. Crane lifting is common at construction sites, ports, factories, and power plants for moving machinery, steel, concrete, and other materials. While handling these heavy materials, the risk of accidents is always there. Crane accidents generally happen due to:

• Overloading the crane
• Damaged slings or hooks
• Poor ground conditions causing the crane to lose stability

To prevent these accidents, this guide lays down safety measures you should follow to control these risks.

Common Crane Hazards and Ways to Control Them

Let us look at the main risks during crane lifting and the simple steps EPC contractors can take to prevent accidents.

Overloading and Crane Failure

Every construction equipment has a maximum load limit. During crane lifting, exceeding this limit can make the crane unstable and may cause it to tip over or fail.

Before lifting a load, the operator and lifting team should check its weight and compare it with the capacity of cranes.

• Check the load capacity: Check the rated capacity indicator before starting the lift.
• Know the load weight: Never guess how much a load weighs. Check the available documents or measure it when needed.
• Check the load chart: Make sure the crane can lift the load at the planned boom position and working radius.

Contact With Power Lines

Overhead power lines create a serious risk during crane operations. During crane lifting, the boom does not always need to touch a power line for electricity to cause an accident.

Workers should identify nearby power lines before positioning the crane.

• Keep a safe distance: Keep the crane boom at least 10 feet away from power lines up to 50 kV.
• Switch off power when possible: Ask the power company to turn off the line or provide suitable protection before work begins.
• Use a spotter: A trained spotter can watch the clearance and warn the operator when the crane gets too close.

Unstable Ground and Outrigger Problems

A crane needs firm and level ground to remain stable. Soft soil, uneven surfaces, or hidden underground spaces can cause the crane to sink or tilt during a lift.

Before setting up for crane lifting, the team should inspect the ground and check whether it can handle the load.

• Check the ground: Inspect the soil and ground condition before placing the crane.
• Use outriggers correctly: Extend the outriggers fully according to the manufacturer's instructions.
• Use crane mats: Place suitable outrigger pads or mats under the outriggers to spread the crane's weight over a larger area.

Falling Loads and Rigging Problems

A poorly secured load can slip or fall during lifting. Damaged slings, hooks, shackles, and wire ropes can also fail while carrying a load.

For this reason, the lifting team should check all rigging equipment before starting work.

• Check rigging equipment: Inspect hooks, shackles, slings, and wire ropes for damage or wear.
• Create a clear lifting zone: Keep workers who are not involved in the lift away from the load path.
• Use tag lines: Tag lines can help workers control the movement and swinging of a suspended load.

Poor Communication and Blind Lifts

Good communication helps the crane operator and lifting team work together safely. The risk increases when the operator cannot see the load during a lift.

Therefore, the operator and signal person should agree on communication methods before starting the job.

• Use standard hand signals: Make sure the operator and signal person understand the same hand signals.
• Use two-way radios: Radios can help the team communicate during blind lifts.
• Stop when signals are unclear: The operator should stop the crane if a signal is confusing or communication is lost.

Summary

Crane safety starts with proper planning and attention to every part of the lifting operation. Workers should check the crane, load, ground, rigging equipment, and work area before lifting. Clear communication also helps prevent mistakes during the job. Regular safety training for operators and lifting teams can further reduce risks while working with cranes.