The safe use of overhead cranes is critical to ensuring both operator safety and the integrity of

the equipment. Overhead cranes are used to lift and move heavy loads within a specific area, and
proper procedures must be followed to avoid accidents, equipment damage, and injury.

✅ Safe Use of Overhead Cranes

1. Pre-Operation Checks

 Visual Inspection:
o Check the hoist, hooks, chains, slings, and other lifting equipment for any visible
wear, cracks, or damage.
o Inspect the crane structure for any deformities, cracks, or signs of excessive
wear.
o Verify that the control panel is functional, and check that all safety features
(emergency stop, limit switches, etc.) are working.
 Load Charts and Capacity:
o Confirm the crane’s load chart is easily accessible and corresponds to the
specific crane model and configuration.
o Do not exceed the crane's rated load capacity, as indicated on the load chart,
ensuring that the load is properly balanced.
 Hoist and Lifting Mechanism:
o Check the brakes for proper operation.
o Ensure the limit switches are functional, and that they prevent the hook or load
from moving beyond safe limits.

2. Safe Lifting Practices

 Use Certified Lifting Gear:

o Ensure that slings, hooks, and lifting devices are properly rated for the weight of
the load.
o Do not use damaged lifting gear, and inspect it regularly for wear.
 Proper Hooking:
o Ensure the hook is properly aligned with the load's center of gravity and securely
positioned to prevent accidental release.
o Avoid side loading or twisting of the hook.
 Ensure Load Stability:
o Center the load on the hook to maintain balance during the lift.
o Use taglines to control the load if necessary, especially for loads that are unstable
or difficult to maneuver.
 Lift Smoothly:
o Lift loads slowly and steadily without sudden movements.
 o Avoid sudden starts, stops, or jerking movements that could cause load swinging
or imbalance.
 Never Lift Over People:
o Never operate the crane with a load above personnel. Always ensure the area
under the load is clear of workers.
 Avoid Swinging:
o Keep the load as close to the crane as possible to avoid swinging. If the load
starts to swing, lower it carefully until the movement stops.

3. Operator Safety

 Operator Training:
o Only qualified and trained personnel should operate overhead cranes.
Operators must be familiar with the crane's functions, load charts, and safety
features.
o Ensure the crane operator is aware of all safety protocols, including emergency
stop procedures and proper communication methods with riggers or signalers.
 Clear Communication:
o Establish clear communication between the crane operator and the signal person
(if applicable). Use standard hand signals or radios if visibility is limited.
 Work in Well-Lit Areas:
o Ensure the area around the crane is well-lit, especially when lifting in dark or
dimly lit environments.
 Emergency Stop Procedures:
o Know where the emergency stop buttons are located, and ensure the crane’s
emergency stop mechanism is functioning at all times.

4. During Operation

 Monitor Load Throughout Lift:

o Continuously monitor the load during the lift, checking for any unusual
movements or signs of instability.
o Never leave a suspended load unattended. Always ensure that the load is
lowered safely or secured when the crane is not in use.
 Movement Path:
o Ensure the path of movement is clear of obstacles and personnel.
o Use the crane in a controlled manner, avoiding fast or sudden movements.
 Avoid Overloading:
o Do not exceed the maximum load capacity of the crane, especially when lifting
at an extended radius or height.
o Check the load to ensure it is properly balanced and centered to avoid tipping.
 Check Environmental Conditions:
 o Do not operate the crane in high winds, thunderstorms, or other adverse weather
conditions that could affect visibility or crane stability.

5. After Use

 Lower Load Safely:

o Once the load has been placed or moved to the correct location, lower the load
slowly and steadily and release it gently.
 Power Off and Secure the Crane:
o Turn off the crane and engage the parking brake if applicable.
o Remove the key (if applicable) and secure the crane in a safe position.
 Report Faults and Issues:
o Immediately report any malfunctions, damage, or operational issues to the
maintenance team for review and repair.

6. Routine Maintenance and Inspections

 Regular Inspections:
o Perform regular pre-shift inspections of the crane and lifting equipment to ensure
everything is in safe working condition.
 Schedule Professional Inspections:
o Have the crane inspected by a qualified professional at regular intervals, as per
the manufacturer’s guidelines, or following a heavy use or incident.
 Lubrication and Maintenance:
o Ensure moving parts, such as the hoist, gears, and controls, are adequately
lubricated to reduce wear and improve performance.
 Cleanliness:
o Keep the crane free from dirt, debris, and materials that could affect its operation
or safety.

7. Common Hazards to Avoid

 Crane Tipping or Overturning:

o Ensure the crane is on stable, level ground. Avoid operating on uneven surfaces or
near edges where the crane could tip.
 Electrical Hazards:
o Maintain a safe distance from power lines (typically at least 10 feet/3 meters)
to avoid electrocution risks. Ensure the crane is grounded and insulated if
working near power lines.
 Injury from Swinging Loads:
 oAlways ensure that the area below the crane's load path is clear of people and
obstacles.
 Mechanical Failure:
o Avoid using damaged or untested cranes and lifting equipment. Ensure the crane
is properly maintained and regularly inspected.

⚠️ Emergency Procedures

 Load or Crane Malfunction:

o Stop the operation immediately and evaluate the situation. Do not continue
lifting if there is a malfunction or if the crane is unstable.
o If the crane starts to tip or collapse, immediately evacuate the area and call for
emergency assistance.
 Operator Injury:
o In case of operator injury, stop the crane and immediately call for medical
assistance.
o Ensure the injured person is not in danger from the crane's operation or the
suspended load.

Here's a Safety Checklist for the safe use of overhead cranes. This checklist can be used daily
before operating the crane to ensure all safety protocols are followed.

✅ Overhead Crane Safety Checklist

1. Pre-Operation Checks

 🔲 Visual Inspection:
o Inspect the hoist, hook, chains, and lifting equipment for visible damage (wear,
cracks, corrosion).
o Check the crane structure (boom, gantry, rails) for any deformities or signs of
wear.
o Ensure the control panel and all buttons are functional.
o Verify the crane has valid inspection certificates.
 🔲 Load Charts and Capacity:
o Confirm the crane’s load chart is accessible and up-to-date.
o Ensure the load does not exceed the rated capacity (crane, hook, or lifting
equipment).
 🔲 Hoist and Lifting Mechanism:
o Check the brakes for proper operation.
 o Test the limit switches to confirm they prevent the load from moving beyond safe
limits.

2. Safe Lifting Practices

 🔲 Use Certified Lifting Gear:

o Ensure slings, shackles, and lifting devices are rated for the load being lifted.
o Inspect slings and ropes for wear, corrosion, or damage.
 🔲 Proper Hooking:
o Ensure the hook is centered and securely positioned on the load.
o Never side-load the hook or twist it during operation.
 🔲 Ensure Load Stability:
o Verify the load is properly balanced and aligned with the hook before lifting.
o Use taglines to control the load if necessary.
 🔲 Lift Smoothly:
o Begin the lift slowly and steadily.
o Avoid jerking or rapid movements that could cause load instability.
 🔲 Never Lift Over People:
o Never operate the crane with a load over personnel. Ensure the area under the
load is clear of workers.
 🔲 Avoid Load Swinging:
o Keep the load as close to the crane as possible to prevent swinging.

3. Operator Safety

 🔲 Operator Training:
o Ensure the operator is qualified and has been properly trained on the crane's
operations, safety features, and load charts.
 🔲 Clear Communication:
o Use standard hand signals or two-way radios to communicate with signalers or
riggers.
 🔲 Work Area Lighting:
o Ensure the work area is well-lit, especially in low-visibility conditions.
 🔲 Emergency Stop Procedures:
o Ensure the emergency stop buttons are easily accessible and functional.

4. During Operation
  🔲 Monitor Load During Lift:
o Continuously monitor the load for unusual movements or signs of instability.
o Never leave a suspended load unattended.
 🔲 Clear Movement Path:
o Confirm that the path of the crane is free from obstacles and personnel.
 🔲 Avoid Overloading:
o Ensure the crane is within its rated capacity and the load is balanced.
 🔲 Check Environmental Conditions:
o Ensure that there are no adverse weather conditions (high winds, lightning, etc.)
that could affect crane stability.

5. After Use

 🔲 Lower Load Safely:

o Lower the load slowly to its final position and ensure it is secured properly.
 🔲 Power Off and Secure the Crane:
o Turn off the crane and engage the parking brake.
o Remove the key if applicable and secure the crane in its rest position.
 🔲 Report Faults:
o Immediately report any malfunctions, damage, or operational issues to the
maintenance team.

6. Routine Maintenance & Inspections

 🔲 Pre-Shift Inspections:
o Conduct daily visual inspections of the crane and lifting gear.
 🔲 Periodic Inspections:
o Schedule regular inspections of the crane by qualified personnel per the
manufacturer's guidelines.
 🔲 Lubrication:
o Ensure that all moving parts are adequately lubricated.
 🔲 Cleanliness:
o Keep the crane clean and free of dirt, debris, and any materials that could affect
operation.

Notes:
 Safety First! Never operate a crane unless all checks have been performed and the crane
is in safe working order.
 Emergency Procedures: Ensure all personnel are familiar with emergency stop and
evacuation procedures in the event of a malfunction, crane tip-over, or load failure.