Crane & Rigging Safety Manual

Crane & Rigging Safety Programs

The safety programs needed by a company depend on the lifting equipment used and the work performed. A comprehensive manual may include programs covering:

• Crane Safety
• Rigging and Material Handling
• Overhead Crane Safety
• Critical Lift Planning
• Qualified Rigger Safety
• Signal Person Safety
• Personal Protective Equipment
• Fall Protection
• Electrical and Overhead Power Line Safety
• Heavy Equipment Safety
• Forklift and Powered Industrial Truck Safety
• Aerial Lift Safety
• Lockout/Tagout
• Job Safety Analysis
• Hand and Power Tool Safety
• Hazard Communication
• Emergency Action Plan
• First Aid
• Heat Stress Prevention
• Safety Audits and Inspections

Programs that do not apply to the company’s operations can be removed, while additional programs should be included when specialized lifting operations create additional hazards.

Crane and Hoisting Safety

Crane operations should be planned and performed so loads can be lifted, moved, and placed without exposing employees to unnecessary hazards.

Planning should consider:

• Crane type and configuration
• Load weight
• Load dimensions
• Load center of gravity
• Crane capacity
• Lift radius
• Boom length and angle
• Ground conditions
• Crane setup
• Rigging
• Travel path
• Load landing area
• Power lines
• Nearby structures
• Employees in the area
• Weather
• Communication
• Simultaneous operations

Employees involved in the lift should understand their responsibilities before lifting begins.

Crane Operator Qualifications

Crane operators should possess the training, certification or licensing, and qualifications required for the equipment and work being performed.

Operators should understand:

• Equipment controls
• Operating characteristics
• Load charts
• Rated capacities
• Safety devices
• Operational aids
• Inspection requirements
• Setup requirements
• Limitations
• Emergency procedures

Operators should not operate equipment beyond their qualifications or authorization.

Crane Operator Responsibilities

The crane operator is responsible for controlling the equipment safely within its operating limitations.

Operators should:

• Perform required inspections.
• Understand the crane configuration.
• Verify capacity for the planned lift.
• Follow load charts and manufacturer requirements.
• Respond only to appropriate signals.
• Stop operations when communication is lost.
• Remain alert to employees and equipment.
• Maintain required electrical clearances.
• Avoid shock loading.
• Stop operations when conditions become unsafe.

An operator should obey a stop or emergency-stop signal regardless of who gives it.

Qualified Riggers

Employees performing rigging work should be qualified for the specific rigging tasks they perform when qualification is required.

A qualified rigger should understand applicable:

• Sling types
• Hitch configurations
• Sling angles
• Rigging hardware
• Load weights
• Load balance
• Centers of gravity
• Working load limits
• Inspection criteria
• Removal-from-service criteria
• Load-control methods

The complexity of the lift should determine the level of rigging knowledge and experience required.

Qualification for one type of rigging work does not necessarily mean an employee is qualified for every rigging operation.

Signal Persons

Signal persons should be qualified when required and should understand the signals and equipment characteristics relevant to the operation.

Signal-person knowledge should include:

• Standard hand signals
• Voice signals
• Radio communication
• Crane limitations related to signaling
• Signal-person positioning
• Communication procedures

Only one person should normally give operational signals to the crane operator at a time, except that anyone may give a stop or emergency-stop signal.

Lift Planning

Every crane lift should receive an appropriate level of planning.

Routine lifts may require relatively simple planning, while complex or unusual lifts may require written procedures, engineering review, specialized rigging, or a formal critical-lift plan.

Lift planning should address:

• Load weight
• Load dimensions
• Center of gravity
• Crane capacity
• Rigging configuration
• Sling angles
• Lift radius
• Load path
• Landing location
• Ground conditions
• Power lines
• Personnel
• Weather
• Communication
• Emergency considerations

Changes that could affect the lift should be evaluated before proceeding.

Critical Lifts

The company should establish criteria for identifying lifts requiring additional planning and approval.

Depending on company or customer requirements, critical lifts may include lifts involving:

• High percentages of crane capacity
• Multiple cranes
• Personnel
• Unusual or valuable equipment
• Hazardous materials
• Loads over occupied areas
• Difficult rigging configurations
• Limited clearances
• High-consequence equipment
• Other unusually hazardous conditions

Critical lifts should be planned by personnel with appropriate knowledge and authority.

The plan may document crane configuration, load information, rigging, capacity calculations, personnel, communication, environmental limitations, and approval requirements.

Multiple-Crane Lifts

Lifts involving more than one crane require careful planning because load distribution can change as the load moves.

Planning should address:

• Load weight
• Load distribution
• Crane capacities
• Rigging
• Lift sequence
• Crane movement
• Communication
• Personnel responsibilities

Multiple-crane lifts should be directed by appropriately qualified personnel.

Crane Selection

The crane selected for a lift should be suitable for the intended operation.

Selection should consider:

• Load weight
• Required radius
• Required height
• Boom configuration
• Ground conditions
• Access
• Setup space
• Environmental conditions
• Manufacturer limitations

A crane should not be selected solely because its maximum rated capacity exceeds the weight of the load.

Actual capacity depends on crane configuration and operating radius.

Load Charts

Crane operators and personnel responsible for lift planning should understand the applicable load chart.

Capacity may be affected by:

• Operating radius
• Boom length
• Boom angle
• Jib configuration
• Counterweight
• Parts of line
• Outrigger configuration
• Crane configuration

The crane should not be operated beyond the applicable rated capacity.

Required load-chart information should be available to the operator.

Determining Load Weight

The weight of the load should be determined before lifting.

Sources may include:

• Manufacturer information
• Shipping documents
• Engineering drawings
• Equipment nameplates
• Calculations
• Reliable weighing methods

Rigging, lifting beams, spreader bars, hooks, blocks, and other lifting accessories should be included when determining the total load imposed on the crane.

Load weight should not be guessed when an inaccurate estimate could affect crane capacity or rigging selection.

Center of Gravity and Load Stability

The rigging arrangement should account for the load’s center of gravity.

The hook should normally be positioned so the load can remain stable when lifted.

An improperly balanced load may:

• Tilt
• Shift
• Rotate
• Slip from the rigging
• Overload individual sling legs

A test lift may be used when appropriate to verify balance and rigging before raising the load higher.

Ground Conditions

Crane stability depends heavily on adequate ground support.

Before setup, evaluate:

• Soil
• Compaction
• Underground utilities
• Voids
• Vaults
• Trenches
• Excavations
• Backfilled areas
• Slopes
• Drainage
• Frozen or thawing ground
• Nearby structures

Ground conditions should be firm, drained, and graded to a sufficient extent so the equipment manufacturer’s specifications for adequate support and level can be met.

Conditions should continue to be monitored during crane operations.

Crane Setup

Cranes should be set up according to manufacturer requirements and the planned configuration.

Setup should address:

• Equipment location
• Level
• Ground support
• Outriggers
• Stabilizers
• Mats or cribbing
• Counterweights
• Barricades
• Swing radius
• Power lines
• Access

Setup should be verified before lifting operations begin.

Outriggers and Stabilizers

Outriggers and stabilizers should be deployed according to the crane configuration and manufacturer requirements.

Outrigger floats should be properly supported.

Mats, cribbing, or other support should be appropriate for the loads and ground conditions.

Employees should keep hands, feet, and other body parts clear of pinch and crush points during deployment and retraction.

Crane Assembly and Disassembly

Assembly and disassembly can expose employees to unstable components, falls, pinch points, suspended loads, and stored energy.

Operations should be directed by personnel meeting applicable requirements.

Planning should consider:

• Manufacturer procedures
• Component weights
• Support
• Rigging
• Fall protection
• Employee positioning
• Pin removal
• Stored energy
• Stability

Employees should remain clear of areas where components could move unexpectedly.

Crane Inspections

Cranes should receive inspections required for the equipment and circumstances.

Inspections may include:

• Shift inspections
• Monthly inspections
• Annual or comprehensive inspections
• Post-assembly inspections
• Inspections following repairs or modifications
• Inspections following certain equipment events

Inspection requirements depend on the crane, applicable regulations, manufacturer requirements, and work performed.

Deficiencies affecting safe operation should be corrected before continued use when required.

Pre-Operation Inspection

Before operation, the crane should be inspected for conditions that could affect safe use.

Items may include:

• Controls
• Brakes
• Wire rope
• Hooks
• Safety devices
• Operational aids
• Hydraulic systems
• Tires
• Tracks
• Outriggers
• Fluid leaks
• Electrical components
• Warning devices

Operators should report deficiencies according to company procedures.

Wire Rope

Crane wire rope should be inspected and maintained according to applicable requirements and manufacturer criteria.

Inspection should consider conditions such as:

• Broken wires
• Kinking
• Crushing
• Birdcaging
• Corrosion
• Abrasion
• Heat damage
• Diameter reduction
• Damaged end connections

Wire rope meeting removal criteria should be taken out of service as required.

Hooks

Hooks should be inspected for damage or conditions that could affect safe use.

Potential defects include:

• Cracks
• Excessive wear
• Twisting
• Throat opening
• Deformation
• Heat damage

Hooks should not be modified, welded, or repaired unless the procedure is appropriate and authorized.

Safety latches should be used when required or appropriate for the operation.

Rigging Equipment

Rigging equipment should be suitable for the intended load and environment.

Common equipment includes:

• Wire-rope slings
• Alloy-chain slings
• Synthetic web slings
• Synthetic round slings
• Shackles
• Hooks
• Eyebolts
• Hoist rings
• Spreader beams
• Lifting beams

Rigging equipment should have adequate capacity for the planned load and configuration.

Rigging Inspections

Rigging equipment should be inspected as required before use and during service.

Employees should look for:

• Cuts
• Tears
• Abrasion
• Broken wires
• Kinks
• Crushing
• Corrosion
• Heat damage
• Chemical damage
• Cracked fittings
• Bent hardware
• Missing identification
• Excessive wear

Rigging equipment that does not meet applicable inspection criteria should be removed from service.

Sling Selection

Slings should be selected based on the load and lifting conditions.

Selection should consider:

• Load weight
• Hitch
• Sling angle
• Load shape
• Edges
• Temperature
• Chemical exposure
• Environment
• Required capacity

Employees should not exceed the rated capacity of a sling.

Sling Angles

Sling angle can significantly affect tension.

As sling angles decrease from vertical, tension in the sling legs increases.

Employees responsible for rigging should understand how sling angles affect loading and should select rigging with sufficient capacity for the actual configuration.

Very low sling angles should be avoided unless specifically evaluated and appropriate equipment is used.

Hitch Configurations

Common sling configurations include:

• Vertical hitches
• Choker hitches
• Basket hitches
• Multiple-leg bridle arrangements

The hitch should be appropriate for the load and should prevent unintended movement.

Capacity should be determined using the manufacturer’s information for the actual hitch and configuration.

Sharp Edges

Slings should be protected from sharp edges when necessary to prevent damage.

Edge protection should be appropriate for the sling material and load.

Employees should not rely on improvised protection that can easily move, collapse, or be cut through during the lift.

Shackles and Rigging Hardware

Shackles, eyebolts, hoist rings, hooks, and other rigging hardware should be:

• Identifiable
• Properly rated
• Inspected
• Correctly installed
• Compatible with the rigging system

Bolts, makeshift pins, or other improvised components should not be substituted for proper rigging hardware.

Side loading should be avoided unless the hardware is designed and rated for it.

Spreader and Lifting Beams

Spreader beams and lifting beams should be suitable for the intended load and properly marked or otherwise identified as required.

Rigging personnel should understand:

• Beam capacity
• Attachment points
• Sling arrangement
• Load distribution
• Manufacturer restrictions

Damaged or modified lifting devices should be evaluated before further use.

Below-the-Hook Lifting Devices

Specialized lifting devices may include:

• Magnets
• Vacuum lifters
• Plate clamps
• Drum lifters
• Coil lifters
• Concrete lifting devices
• Custom lifting fixtures

Employees should follow manufacturer requirements and applicable rated capacities.

Custom or engineered lifting devices should receive appropriate design and inspection consideration.

Tag Lines and Load Control

Tag lines or other load-control methods should be used when necessary to control rotation or movement.

Employees using tag lines should:

• Remain clear of the load.
• Avoid wrapping lines around hands or body.
• Maintain an escape route.
• Avoid pinch points.
• Remain clear of equipment travel paths.

Tag lines should not be used in a manner that creates an electrical or entanglement hazard.

Suspended Loads

Employees should avoid being directly beneath suspended loads.

Lift planning should minimize situations where loads travel over employees.

Employees involved in hooking, unhooking, guiding, or receiving loads should position themselves to minimize exposure to falling or shifting loads.

A suspended load should not be left unattended when doing so could create a hazard.

Fall Zone

Access to areas where employees could be struck by a falling load should be controlled as appropriate.

Only employees necessary for the operation should enter the fall zone when exposure exists.

Rigging and load-handling procedures should minimize the amount of time employees must work close to suspended loads.

Landing Loads

The load landing area should be prepared before the load arrives.

Planning should consider:

• Adequate space
• Support
• Blocking
• Stability
• Employee access
• Pinch points
• Rigging removal

Employees should keep hands and feet out of areas where the load could shift or settle.

Hands should not be used to position loads where pinch points exist.

Hand Signals

Standard crane hand signals should be used when hand signaling is selected.

Signal persons and operators should understand the signals before operations begin.

Signal charts should be posted when required.

Non-standard signals should be agreed upon before lifting begins and should not conflict with standard signals.

Radio and Voice Communication

Radios may be used when the operator and signal person cannot maintain visual contact.

Communication should be:

• Clear
• Reliable
• Appropriate to the operation
• Understood by the operator and signal person

When communication is interrupted, the operator should stop movement until communication is restored.

Blind Lifts

A blind lift occurs when the operator cannot directly see the load or load path during some or all of the operation.

Blind lifts require effective communication with a qualified signal person.

Planning should ensure the signal person can safely observe the load, travel path, or other necessary conditions.

Additional signal persons may be needed for complex load paths, with communication procedures established before the lift.

Overhead Power Lines

Electrical contact with overhead power lines is one of the most serious crane hazards.

Power lines should be identified during lift planning and crane setup.

Planning should consider:

• Crane location
• Boom movement
• Load movement
• Rigging
• Tag lines
• Assembly and disassembly
• Crane travel
• Required clearance

Required power-line precautions and minimum approach distances should be established before operations begin.

Employees should treat power lines as energized unless their status has been appropriately confirmed and required protective measures established.

Crane Travel

Cranes traveling with or without loads should follow manufacturer requirements and site procedures.

Before travel, evaluate:

• Route
• Ground conditions
• Slopes
• Overhead obstructions
• Power lines
• Pedestrians
• Other equipment
• Load position
• Boom configuration

A spotter or signal person should be used when necessary to safely control movement.

Swing Radius

Employees can be crushed between the rotating superstructure of a crane and fixed objects.

Where employees could enter a hazardous swing-radius area, appropriate controls should be established.

Controls may include:

• Barricades
• Warning lines
• Restricted access
• Employee instruction

Employees should not enter a crane’s crush zone without establishing appropriate communication and controls.

Working Around Mobile Cranes

Employees working around cranes should understand:

• Equipment blind spots
• Swing radius
• Counterweight movement
• Suspended loads
• Outriggers
• Travel paths
• Signal procedures

Ground employees should establish communication with operators before entering equipment operating areas.

Overhead and Gantry Cranes

Facilities using overhead or gantry cranes should establish procedures appropriate to those systems.

Safety considerations may include:

• Operator training
• Pre-use inspection
• Rated capacity
• Hooks
• Hoist ropes or chains
• Limit devices
• Pendant controls
• Radio controls
• Load travel
• Rigging
• Employee positioning

Loads should not be moved over employees when avoidable.

Hoists

Chain hoists, lever hoists, electric hoists, air hoists, and other lifting equipment should be selected and used within their rated capacities.

Employees should inspect hoists before use as appropriate.

Hoists should not be used with damaged hooks, chains, wire ropes, controls, or other components.

Employees should not extend handles, overload hoists, or use equipment contrary to manufacturer instructions.

Material Handling

Crane and rigging operations frequently involve material staging, loading, unloading, and equipment positioning.

Materials should be:

• Stable
• Properly supported
• Stored to prevent movement
• Accessible for safe rigging
• Protected against unintended displacement

Employees should avoid climbing on unstable materials to attach or remove rigging.

Loading and Unloading Trucks

Loading and unloading can expose employees to suspended loads, shifting materials, vehicle movement, and falls.

Before lifting:

• Stabilize the vehicle when necessary.
• Evaluate the load.
• Establish an appropriate lifting area.
• Keep unnecessary employees clear.
• Inspect rigging.
• Establish communication.

Employees should anticipate that materials may shift when straps, chains, binders, or restraints are released.

Personal Protective Equipment

PPE should be selected based on the hazards of the work.

Common crane and rigging PPE may include:

• Hard hats
• Safety glasses
• Work gloves
• Safety-toe footwear
• High-visibility apparel
• Hearing protection
• Fall protection
• Other task-specific PPE

Employees should inspect PPE before use and replace damaged equipment.

Fall Protection

Crane assembly, maintenance, inspection, and other activities may expose employees to falls.

Fall hazards should be evaluated before elevated work begins.

Employees should use required:

• Guardrails
• Personal fall arrest systems
• Positioning systems
• Access systems
• Other appropriate protection

Fall-protection equipment should be inspected before use.

Ladders and Access

Employees should use designated crane access systems and appropriate ladders when needed.

Employees should:

• Maintain three points of contact.
• Keep hands free while climbing when practical.
• Use appropriate access points.
• Keep steps and platforms clean.
• Avoid jumping from equipment.

Damaged access systems should be reported and corrected.

Weather Conditions

Weather can significantly affect crane and rigging operations.

Conditions requiring evaluation may include:

• High winds
• Lightning
• Heavy rain
• Ice
• Snow
• Extreme heat
• Extreme cold
• Reduced visibility

Wind can affect both crane stability and load control, particularly with large loads having substantial surface area.

Operations should be modified or suspended when conditions exceed manufacturer limitations or otherwise make the lift unsafe.

Wind and Load Control

Wind effects depend on more than load weight.

Large panels, tanks, ductwork, roofing materials, structural components, and similar loads can develop substantial wind forces.

Lift planning should consider:

• Wind speed
• Wind direction
• Load surface area
• Load shape
• Lift height
• Crane manufacturer limitations

Employees should not attempt to physically overpower an uncontrolled load.

Heat and Cold Stress

Crane and rigging employees may work outdoors in extreme temperatures while performing physically demanding tasks.

Heat-stress controls may include:

• Drinking water
• Rest
• Shade
• Acclimatization
• Work scheduling

Cold-stress controls may include:

• Appropriate clothing
• Warming opportunities
• Protection from wind and moisture
• Monitoring for cold-related illness

Weather conditions should also be considered when handling metal rigging components.

Lockout/Tagout

Maintenance and repair of cranes, hoists, and related equipment may expose employees to hazardous energy.

Hazardous energy may include:

• Electrical
• Mechanical
• Hydraulic
• Pneumatic
• Gravity
• Stored energy

Required energy-control procedures should be implemented before servicing or maintenance begins.

Elevated or suspended components should be lowered or otherwise safely supported when necessary.

Crane Maintenance

Only appropriately qualified and authorized employees should perform crane maintenance.

Maintenance procedures should address:

• Hazardous energy
• Elevated components
• Hydraulic pressure
• Electrical hazards
• Access
• Falls
• Moving components
• Manufacturer instructions

Equipment should not be returned to service until required repairs and inspections have been completed.

Working Near Other Equipment

Crane operations may interact with:

• Forklifts
• Aerial lifts
• Excavators
• Trucks
• Loaders
• Other cranes
• Construction equipment

Work should be coordinated to prevent equipment conflicts.

Travel paths, swing areas, suspended loads, and employee work zones should be considered during planning.

Job Safety Analysis

A Job Safety Analysis (JSA) can help identify crane and rigging hazards before lifting operations begin.

JSAs may be appropriate for:

• Mobile crane operations
• Crane setup
• Crane assembly and disassembly
• Routine lifting
• Critical lifts
• Multiple-crane lifts
• Blind lifts
• Rigging
• Equipment setting
• Loading and unloading
• Overhead crane operations
• Crane work near power lines
• Crane maintenance
• Personnel lifting when applicable

The JSA should identify the steps of the task, associated hazards, and controls needed to perform the work safely.

A lift plan and JSA serve different purposes and may both be appropriate for higher-risk operations.

Emergency Procedures

Crane and rigging operations should include planning for foreseeable emergencies.

Potential emergencies include:

• Dropped loads
• Crane instability
• Equipment contact with power lines
• Rigging failure
• Employee injury
• Equipment failure
• Severe weather
• Fire

Employees should know how to stop operations, secure the area, summon assistance, and prevent additional employees from entering hazardous areas.

Employees should not approach a crane involved in electrical contact until the electrical hazard has been appropriately controlled.

Crane and Rigging Safety Training

Employees should receive training appropriate to their assigned responsibilities.

Training may include:

• Crane hazards
• Operator responsibilities
• Rigging
• Signal-person duties
• Load charts
• Lift planning
• Critical lifts
• Suspended loads
• Electrical hazards
• Fall zones
• Crane setup
• Ground conditions
• Equipment inspections
• Fall protection
• PPE
• Emergency procedures

Training, certification, qualification, and evaluation records should be maintained as applicable to the employee’s duties.

Retraining should be provided when changing equipment, conditions, work practices, or employee performance indicate additional instruction is necessary.

Building a Crane & Rigging Safety Manual

A Crane & Rigging Safety Manual should be customized to the company’s actual lifting operations rather than relying solely on a generic construction or material-handling safety manual.

A company occasionally using a small mobile crane for routine material placement may require a different combination of procedures than a crane contractor performing engineered lifts, equipment setting, industrial shutdowns, tandem lifts, structural construction, or complex rigging operations.

Likewise, a manufacturing facility operating overhead cranes and hoists may have substantially different procedures from a construction contractor operating lattice-boom and telescopic mobile cranes.

The manual should reflect the cranes, hoists, rigging equipment, lifting devices, employees, operator qualifications, signal-person responsibilities, qualified riggers, lift-planning procedures, inspections, maintenance operations, and customer work environments applicable to the company.

The completed safety manual should provide practical procedures employees and supervisors can use while supporting OSHA compliance, employee training, qualification requirements, lift planning, JSAs, inspections, incident investigations, customer requirements, and the company’s overall safety-management system.

Customized Crane & Rigging Safety Manuals

Get a Crane & Rigging Safety Manual customized for your mobile cranes, overhead cranes, hoists, rigging equipment, critical lifts, equipment setting, loading and unloading, qualified riggers, signal persons, power-line exposures, suspended loads, and other crane and rigging hazards.