20 Crane Operator Safety Tips

Twenty safety tips for crane operators, riggers, and signalpersons, in order, from the CertLok Safety Tip series. Each tip has a short checklist, a bottom line, and the source behind it. Share them with your crew.

Terms used on this page: OSHA means Occupational Safety and Health Administration; CFR means Code of Federal Regulations; CPWR means the Center for Construction Research and Training; mph means miles per hour; CCO means Certified Crane Operator; CDL means commercial driver's license.

General safety information only. Always follow your employer's safety program and the official OSHA standards.

Crane Operator Safety Tip #1: Respect Power Lines

Respect power lines. They don't give second chances.

According to the Center for Construction Research and Training (CPWR), 157 construction workers died from crane contact with overhead power lines between 1992 and 2006. That was 1 in 4 of all crane-related deaths in that time. More than half of them were on the ground, touching or guiding the load.

Before the lift:

• Find the overhead power lines before the crane shows up.
• Work with the power company to shut off and ground the lines when you can.
• Keep the minimum distance the Occupational Safety and Health Administration (OSHA) requires.
• Mark off the work zone, use a spotter when the rules call for one, and keep talk clear.
• Cover power lines in every pre-lift talk.

Bottom line: power line safety starts when the job is planned.

Crane operators, linemen, riggers, groundmen, and more all count on that plan. So plan the lift, and make sure your crew's certifications are current and in one place.

Source: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), Table 1 and Table 2

Crane Operator Safety Tip #2: Brief the Crew. Every Pick.

Your pre-lift meeting starts with one question: is everyone here qualified for this pick? With CertLok, every certification is already on every phone. Crane operators, riggers, and signalpersons can show their certs in seconds. No digging through trucks. No texting photo copies.

Then you can spend the meeting on what matters: the lift.

According to the Center for Construction Research and Training (CPWR), 132 construction workers were killed by a crane load from 1992 to 2006. About 1 in 3 of them were not even part of the crane work.

Before every pick:

• Brief the whole crew: the lift director, crane operator, riggers, and signalperson.
• Go over who does what, and who gives the signals.
• Walk through the lift, step by step.
• Name the site hazards and the emergency plan.
• Have everyone's certs ready on their phones.

Bottom line: a five-minute talk can save a life.

Crane operators, riggers, groundmen, and more all count on that talk. So brief the crew every pick, and keep your certifications current and in one place with CertLok.

Source: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), "Details of causes," page 4

Crane Operator Safety Tip #3: Know the Full Weight

Before the pick, two things have to be right: the weight, and the person in the seat. CertLok handles the second one. Your crane operator can show, on their phone and in seconds, that they're certified for that crane. We verify credentials like your CCO card and CDL.

Now get the weight right.

According to the Center for Construction Research and Training (CPWR), crane collapses killed 89 construction workers from 1992 to 2006. Overloading the crane caused 10 of those deaths.

Before every pick:

• Find the real weight of the load. Don't guess.
• Add the hook block, slings, and all the rigging.
• Check the total against the crane's load chart for that setup.
• Never go over net capacity, meaning what the crane can lift once all of that is counted.
• Make sure the operator is certified for that crane.

Bottom line: count every pound, every pick.

Crane operators, riggers, groundmen, and more all count on those numbers. So check the weight, and keep your certifications current and in one place with CertLok.

Source: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), "Details of causes," pages 4 and 5

Crane Operator Safety Tip #4: Check the Crane Every Shift

Every shift, someone has to look the crane over before it works. Make sure that person is qualified. With CertLok, their certifications are current, in one place, and on their phone, ready to show in seconds.

According to the Occupational Safety and Health Administration (OSHA), a competent person must start a visual check of the crane before every shift it will be used. If they find a safety hazard, the crane comes out of service until it's fixed.

Every shift:

• Look the crane over before it works.
• Check the wire rope for kinks, broken wires, and wear.
• Check the hooks and make sure the safety latches close.
• Test the brakes and the controls.
• If something fails, tag it and take the crane out of service.

Bottom line: small problems are cheap to find before the first pick.

Crane operators, riggers, heavy equipment operators, and more all count on that check. So check it every shift, and keep your certifications current and in one place with CertLok.

Source: OSHA, 29 CFR 1926.1412(d), "Inspections: Each shift."

Crane Operator Safety Tip #5: Inspect Rigging Hardware Before Every Use

The rigger inspecting your gear should be qualified, and able to prove it. With CertLok, their certifications are already on their phone, ready to show in seconds. No digging through trucks. No texting photo copies.

Then the crew can focus on the gear itself.

According to the Center for Construction Research and Training (CPWR), 132 construction workers were killed by a crane load from 1992 to 2006. In 8% of those deaths, straps, buckles, safety latches, or sling clips failed or broke.

Before every use:

1. Check every sling, shackle, and choker.
2. Look over spreader bars and hooks.
3. Look for cuts, kinks, broken wires, wear, and heat damage.
4. Tag damaged gear and pull it from service right away.
5. Have your certs ready on your phone.

Bottom line: bad gear doesn't get a second lift.

Crane operators, riggers, groundmen, and more all count on that check. So inspect the gear every time, and keep your certifications current and in one place with CertLok.

Source: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), "Details of causes," page 4

Crane Operator Safety Tip #6: Protect Slings with Edge Softeners

Good rigging starts with a qualified rigger. With CertLok, riggers keep their certifications in one digital wallet on their phone and share them in seconds. No texting photo copies. No "I'll bring it tomorrow."

Then the crew can focus on the edges that cut slings.

According to the Center for Construction Research and Training (CPWR), 132 construction workers were killed by a crane load from 1992 to 2006. In 14% of those deaths, a rigging cable or strap broke.

Before every lift:

• Find every sharp corner and rough edge on the load.
• Put a softener or pad between the sling and the edge.
• Use softeners on synthetic webbing and on wire rope.
• Make sure the pads stay in place as the load lifts.
• Pull any cut or worn sling from service.

Bottom line: a sharp edge under tension can cut a sling in seconds.

Crane operators, riggers, groundmen, and more all count on that sling. So pad the edges every lift, and keep your certifications current and in one place with CertLok.

Source: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), "Details of causes," page 4

Crane Operator Safety Tip #7: Set Up on Stable, Level Ground

Before the outriggers go down, the site wants to see the operator's certifications. With CertLok, they're on the operator's phone, ready to show in seconds. We verify credentials like your CCO card and CDL.

Then the crew can focus on what's under the crane.

According to the Center for Construction Research and Training (CPWR), crane collapses killed 89 construction workers from 1992 to 2006. An unstable, uneven, or icy surface under the crane caused 12 of those deaths.

Before every setup:

• Check that the ground is firm and can carry the load.
• Extend the outriggers all the way.
• Set the pads on proper cribbing or mats, at least 3 times the pad size.
• Level the crane within 1 degree, or the crane maker's spec.
• Have your certs ready on your phone.

Bottom line: a crane is only as steady as the ground under it.

Crane operators, riggers, groundmen, heavy equipment operators, and more all count on a solid setup. So check the ground every time, and keep your certifications current and in one place with CertLok.

Source: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), "Details of causes," page 4

Crane Operator Safety Tip #8: Barricade the Swing Radius and Hazard Zone

The crew working inside the barricade should be able to show they belong. With CertLok, every certification is on their phone, ready to show in seconds. No digging through trucks. No texting photo copies.

Then everyone else stays outside the line.

According to the Center for Construction Research and Training (CPWR), 30 construction workers died from 1992 to 2006 after being caught in or between crane parts. Rules from the Occupational Safety and Health Administration (OSHA) require barriers that mark the area the crane's turning upper works can swing into.

DO:

• Barricade the counterweight swing radius.
• Tape off the fall zone under the load.
• Tell the operator before you step inside.

DON'T:

• Cut through the swing zone.
• Move or step over the barricade.
• Stand under a suspended load.

Bottom line: if you're inside the line, the operator needs to know.

Crane operators, riggers, groundmen, and more all count on a clear zone. So mark it every lift, and keep your certifications current and in one place with CertLok.

Sources: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), "Causes of death" and Table 1; OSHA, 29 CFR 1926.1424(a)(2)(ii), "Work area control: Swing radius hazards."

Crane Operator Safety Tip #9: Put the Hook Right Over the Load's Center of Gravity

Rigging starts with a rigger who knows how, and can prove it. With CertLok, riggers keep their certifications in one digital wallet on their phone and share them in seconds. No texting photo copies. No "I'll bring it tomorrow."

Then the crew can focus on where the hook goes.

According to the Center for Construction Research and Training (CPWR), 132 construction workers were killed by a crane load from 1992 to 2006. In 10% of those deaths, the load shifted or rotated and struck a worker.

Before every lift:

• Find the load's center of gravity before you rig.
• Put the hook directly over it.
• Use sling legs and hitches that keep the load level.
• If it tilts as it comes up, set it down and re-rig.
• Have your certs ready on your phone.

Bottom line: a hook off center means a load that tilts, swings, or slides.

Crane operators, riggers, groundmen, and more all count on a level load. So find the center every time, and keep your certifications current and in one place with CertLok.

Source: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), "Details of causes," page 4

Crane Operator Safety Tip #10: Use Non-Conductive Taglines and Keep Your Hands Off a Suspended Load

The crew guiding a load should be trained, and able to show it. With CertLok, their certifications are on their phone, ready to share in seconds. No digging through trucks. No texting photo copies.

Then the crew can focus on keeping hands off the load.

According to the Center for Construction Research and Training (CPWR), 132 construction workers were killed by a crane load from 1992 to 2006. 14% of those deaths happened while the worker was flagging, directing, or guiding the load. And when a crane works close to power lines, rules from the Occupational Safety and Health Administration (OSHA) say any tag lines must be non-conductive.

Every lift:

• Control the load with a tagline, not your hands.
• Use non-conductive taglines. Near power lines, it's the rule.
• Stay out from under the load and clear of its swing.
• Never wrap a tagline around your hand or body.
• Have your certs ready on your phone.

Bottom line: let the rope do the work. Keep your hands off a suspended load.

Crane operators, linemen, riggers, groundmen, and more all count on that distance. So use a tagline every time, and keep your certifications current and in one place with CertLok.

Sources: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), "Details of causes," page 4; OSHA, 29 CFR 1926.1408(b)(2), power line safety

Crane Operator Safety Tip #11: Do a Trial Lift: A Few Inches Up, Then Check Balance and Brakes

A good trial lift starts with an operator who's qualified, and can prove it. With CertLok, the operator's certifications are on their phone, ready to show in seconds. We verify credentials like your CCO card and CDL.

Then the crew can focus on those first few inches.

According to the Center for Construction Research and Training (CPWR), 132 construction workers were killed by a crane load from 1992 to 2006. In 19% of those deaths, the load came loose from the rigging. Rules from the Occupational Safety and Health Administration (OSHA) also say that when a load is 90% or more of the crane's maximum line pull, the operator must test the brakes by lifting the load a few inches and applying them.

Before every lift:

• Lift the load just a few inches off the ground.
• Stop and hold it there.
• Check that it hangs level and the rigging is seated.
• Make sure the brakes hold.
• If anything is off, set it down and fix it.

Bottom line: a few inches up is the place to find a problem, not fifty feet up.

Crane operators, riggers, groundmen, and more all count on that pause. So test every lift, and keep your certifications current and in one place with CertLok.

Sources: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), "Details of causes," page 4; OSHA, 29 CFR 1926.1417(s), operation

Crane Operator Safety Tip #12: Check Wind Speed at Boom Height and Watch the Sail Effect

Windy days need an operator who's qualified, and able to prove it. With CertLok, operators keep their certifications in one digital wallet on their phone and share them in seconds. No texting photo copies.

Then the crew can focus on the wind up high.

According to the Center for Construction Research and Training (CPWR), a crane known as "Big Blue" collapsed at a stadium in Milwaukee in 1999 in winds of 25 to 30 mph, and three construction workers were killed. Rules from the Occupational Safety and Health Administration (OSHA) say the competent person must adjust the crane or the work for the effect of wind, ice, and snow on the crane's stability and capacity.

Before every lift:

• Check the wind speed at boom height, not just on the ground.
• Know the crane maker's wind limits, and follow them.
• Watch for gusts, not just the average.
• Big, flat loads catch wind like a sail. Take extra care.
• Have your certs ready on your phone.

Bottom line: the wind at the boom tip decides the lift, not the wind at your boots.

Crane operators, riggers, groundmen, and more all feel the wind. So check it up high every time, and keep your certifications current and in one place with CertLok.

Sources: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), Table 5, "Selected Fatal Crane Incidents Involving Bystanders" (citing LaBar, Occupational Hazards, July 1999); OSHA, 29 CFR 1926.1417(n), operation

Crane Operator Safety Tip #13: Use Standard Hand Signals with One Designated Signalperson

The person giving signals should be qualified, and able to show it. With CertLok, signalpersons keep their certifications in one digital wallet on their phone and share them in seconds. No digging through trucks.

Then the crew can focus on one clear voice.

According to the Occupational Safety and Health Administration (OSHA), only one person may give signals to a crane at a time, and hand signals must follow the Standard Method. If the signals are interrupted, the operator must safely stop until they're back and understood. (Anyone can still call a stop. More on that in a later tip.)

Every lift:

• Name one signalperson for the lift.
• Use the standard hand signals.
• Agree on any special signals before the lift starts.
• If the operator loses sight or radio contact, stop.
• Have your certs ready on your phone.

Bottom line: mixed signals drop loads.

Crane operators, riggers, groundmen, and more all count on clear signals. So keep it to one voice, and keep your certifications current and in one place with CertLok.

Source: OSHA, 29 CFR 1926.1419(c)(1), (c)(2), (f), and (h), signals

Crane Operator Safety Tip #14: Verify Crew Qualifications and Certifications

Before the first lift, the site needs to know the crew is qualified. With CertLok, crane operators, riggers, and signalpersons keep their certifications in one digital wallet on their phone and share them in seconds, instead of texting photo copies. CertLok also keeps your Work History in one place. We verify credentials like your CCO card and CDL.

Then the crew can focus on the lift itself.

According to the Occupational Safety and Health Administration (OSHA), every crane operator must be trained, certified or licensed, and evaluated before running a crane. Signalpersons must be qualified before they give any signals. And when workers are hooking, unhooking, or guiding a load in the fall zone, the load must be rigged by a qualified rigger.

Before every job:

• Check that the operator is certified or licensed for that crane.
• Make sure the rigger is qualified.
• Make sure the signalperson is qualified.
• Look for certifications that are current, not expired.
• Keep your own certifications on your phone, ready to share.

Bottom line: a qualified crew is the first safety device on any lift.

Crane operators, linemen, riggers, groundmen, welders, plumbers, pipefitters, shipbuilders, heavy equipment operators, and more all carry certifications that matter. Keep yours current and in one place with CertLok.

Sources: OSHA, 29 CFR 1926.1427(a), operator training, certification, and evaluation; OSHA, 29 CFR 1926.1428(a), signal person qualifications. A rule; OSHA, 29 CFR 1926.1425(c)(3), keeping clear of the load. A rule

Crane Operator Safety Tip #15: Never Carry Loads Over People

Everyone on the ground counts on a qualified operator and rigger. With CertLok, they keep their certifications in one digital wallet on their phone and share them in seconds. No texting photo copies.

Then the crew can focus on the path the load takes.

According to the Occupational Safety and Health Administration (OSHA), crews must use lift paths that keep workers out from under hoisted loads where they can. When a load is hanging still, only a few workers, such as those hooking, unhooking, or guiding it, may be in the fall zone.

Every lift:

• Plan a lift path that stays away from the crew.
• Clear the path before the load moves.
• Warn anyone working near the path.
• Never swing a load over workers.
• Have your certs ready on your phone.

Bottom line: if a load could fall on someone, change the path.

Crane operators, linemen, riggers, groundmen, welders, pipefitters, and more all work near hoisted loads. So plan the path every time, and keep your certifications current and in one place with CertLok.

Source: OSHA, 29 CFR 1926.1425(a) and (b), keeping clear of the load

Crane Operator Safety Tip #16: No Side Loading or Dragging: Lift Straight Up

Straight, clean lifts take a qualified operator. With CertLok, operators keep their certifications in one digital wallet on their phone and share them in seconds. No texting photo copies.

Then the crew can focus on keeping the line straight.

According to the Center for Construction Research and Training (CPWR), 132 construction workers were killed by a crane load from 1992 to 2006. In 11% of those deaths, the crane turned, tilted, or lost control of the load and it struck a worker. Rules from the Occupational Safety and Health Administration (OSHA) say a crane must not be used to drag or pull loads sideways.

Every lift:

1. Get the hook right over the load before you lift.
2. Keep the hoist line straight up and down.
3. Never drag a load across the ground.
4. Never pull a load sideways with the crane.
5. Have your certs ready on your phone.

Bottom line: a crane is built to lift up, not to pull sideways.

Crane operators, riggers, groundmen, heavy equipment operators, and more all count on a straight lift. So keep the line plumb every time, and keep your certifications current and in one place with CertLok.

Sources: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), "Details of causes," page 4; OSHA, 29 CFR 1926.1417(q), operation

Crane Operator Safety Tip #17: Obey Stop Signals: Anyone Can Stop the Lift

A safe crew is a qualified crew, and CertLok makes that easy to show. Your certifications live in one digital wallet on your phone, ready to share in seconds, along with your Work History.

Then the crew can focus on speaking up.

According to the Occupational Safety and Health Administration (OSHA), anyone who becomes aware of a safety problem must alert the operator or signalperson by giving the stop or emergency stop signal. The operator must obey a stop signal, no matter who gives it.

Every lift:

• If you see a problem, give the stop signal. Anyone can.
• The operator stops, no matter who gives the signal.
• Know the emergency stop: both arms out, palms down, moving side to side.
• Restart only when the problem is fixed.
• Have your certs ready on your phone.

Bottom line: a stop signal is never the wrong call.

Crane operators, linemen, riggers, groundmen, heavy equipment operators, and more all have the right to stop the lift. So speak up every time, and keep your certifications current and in one place with CertLok.

Source: OSHA, 29 CFR 1926.1419(j) and 1926.1417(y)

Crane Operator Safety Tip #18: Keep the Load Moment Indicator (LMI) and Anti-Two-Block Devices Working

Safety devices back up a qualified operator. They don't replace one. With CertLok, operators keep their certifications in one digital wallet on their phone and share them in seconds.

Then the crew can focus on the devices that back them up.

According to the Occupational Safety and Health Administration (OSHA), a crane's required safety aids, like the anti-two-block device and the load moment indicator (LMI), must be working before the lift starts, unless approved backup steps are used while one is being repaired. If one stops working during the lift, the operator must safely stop. And the devices never replace the operator's own judgment.

Before every shift:

• Test the LMI before work starts.
• Check the anti-two-block device at the boom tip.
• Never bypass, disconnect, or override a safety device.
• If a device quits mid-lift, stop safely and get it fixed.
• Have your certs ready on your phone.

Bottom line: a safety device only works when it's switched on.

Crane operators, riggers, heavy equipment operators, and more all count on those devices. So keep them on every lift, and keep your certifications current and in one place with CertLok.

Source: OSHA, 29 CFR 1926.1416(b), (c), (d)(3), and (e)(4), operational aids; 1926.1417(k)

Crane Operator Safety Tip #19: Watch the Pinch Points and Crush Hazards

Working around a crane takes trained eyes. With CertLok, your certifications are on your phone, ready to share in seconds, and your Work History stays in one place. No texting photo copies.

Then the crew can focus on where the crane moves.

According to the Center for Construction Research and Training (CPWR), 125 construction workers were killed after being struck by a crane or crane parts from 1992 to 2006. That's 1 in 5 crane-related deaths, and it includes 13 workers run over by a mobile crane.

Every shift:

• Stay clear of the counterweight's swing behind the crane.
• Keep your hands out from between the load and anything solid.
• Stand clear when outriggers move in or out.
• Never stand between the crane and a wall or other equipment.
• Have your certs ready on your phone.

Bottom line: a crane can crush without ever lifting a thing.

Crane operators, riggers, groundmen, welders, heavy equipment operators, and more all work in that space. So know where the crane moves, and keep your certifications current and in one place with CertLok.

Source: CPWR, "Crane-Related Deaths in Construction and Recommendations for Their Prevention" (revised Nov 2009), "Causes of death" (page 4) and Table 1, with its first footnote

Crane Operator Safety Tip #20: Lower the Boom and Secure the Crane in High Winds or Severe Weather

When the weather turns, you want qualified people making the call. With CertLok, their certifications are on their phone, ready to show in seconds. No digging through trucks. No texting photo copies.

Then the crew can focus on the sky.

According to the Occupational Safety and Health Administration (OSHA), when a local storm warning is issued, the competent person must decide whether to follow the crane maker's steps for securing the crane.

When a storm is coming:

• Watch the forecast and storm warnings all day.
• Follow the crane maker's steps to secure the crane.
• Lower or secure the boom the way the maker says.
• With lightning nearby, stop the lift and clear the area.
• Check the crane before you start again.

Bottom line: no lift is worth riding out a storm.

Crane operators, linemen, riggers, groundmen, heavy equipment operators, and more all work under the same sky. So secure the crane when a storm comes, and keep your certifications current and in one place with CertLok.

Source: OSHA, 29 CFR 1926.1417(h), storm warning