Crane Safety Toolbox Talk - Safety Checklist & Resources

Cranes Often Represent the Most Powerful Equipment on Construction Sites

Cranes frequently serve as the largest and strongest pieces of machinery on construction sites. Their immense size and strength enable them to lift and move extremely heavy loads, but these qualities also make them significant potential hazards. Cranes are complex machines that necessitate proper safety training to ensure the well-being of construction crews and bystanders alike.

According to research published by the Bureau of Labor Statistics (BLS) and Occupational Safety and Health Administration (OSHA), approximately 40 construction workers tragically lose their lives each year due to crane-related accidents. As a result, cranes weighing over 2,000 pounds are subject to regulation, and operators must be certified by the National Commission for the Certification of Crane Operators (NCCCO). Companies using cranes are legally accountable for any harm or damage caused to workers, bystanders, and structures—consequently, many businesses opt to purchase specific insurance coverage for cranes.

Crane Safety Toolbox Talks

Pre-Lift Checklist: Critical Items to Monitor

1. First, inspect for overhead obstructions like power lines, trees, and structures.
2. Ensure slings, chains, and straps meet or exceed the lift's rated capacity. Each sling, strap, and chain must have tags indicating the safe working load.
3. Understand potential pinching and crushing hazards around the crane and the load landing area. Clearly mark these areas with paint or chalk so they are visible to the construction crew and bystanders.
4. Securely barricade the swing radius surrounding the crane to prevent unauthorized individuals from entering pinch-point areas.
5. Verify the load's balance and ensure all items are clear of the path of travel.
6. Follow a detailed lift plan for all critical lifts. Distribute copies of the plan to everyone on the job site. Any changes or modifications to the plan should be communicated promptly to all relevant team members.

During Lift Checklist: Critical Items to Monitor

1. Never allow crew or bystanders to walk or work beneath a suspended load.
2. Maintain a safe distance between all persons and the crane while a load is being raised, moved, or lowered.
3. Crane operators must stay focused and attentive during crane operation—no phone calls or texting unrelated to the job.
4. A trained signalman is essential, and the signalman and operator must use standard industry hand signals. Communication between the crane operator and signalman must remain consistent and clear at all times.
5. Only one person should operate a lift or give signals at a time, except in cases of specific hazardous situations. This minimizes the risk of conflicting instructions causing confusion.
6. Use an air horn to signal when a lift begins to alert personnel of what’s overhead. The sound should be loud enough to reach people outside the immediate area who may not be watching the crane.
7. Avoid raising loads higher than necessary.
8. Never leave a load suspended in the air unattended.

Toolbox Talk Outline

• Discuss the current task to be completed.
• Review the checklists provided above.
• Address safety concerns, including the job site environment, potential hazards, use of personal protective equipment (PPE), first aid and medical support, and emergency procedures.
• Allow time for feedback and questions from the job site crew.
• Consider conducting a quick quiz to confirm everyone understands the toolbox talk guidelines.

Safety Equipment: Signs/Stickers, Air Horns, and Lights

Safety Signs/Stickers

Safety signs and stickers are practical and effective tools for communicating risks to the crew and bystanders on the job site. OSHA/ANSI provides guidelines for visual signs that should be used for cranes at construction sites.

Typically, crane warning labels are made from materials like adhesive-backed vinyl, UL polyester, rust-free aluminum, or plastic. Resources such as SafetySign.com and Amazon offer crane signs and stickers.

Consider bilingual signs for areas where multiple languages are commonly spoken.

Sample Safety Signs

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

Air Horns/Audible Alarm Sirens

Before lifting, use an air horn (or audible alarm siren) or a radio-equipped runner to notify everyone nearby to raise awareness and clear the path. After the lift is complete, signal an "all clear" to inform personnel. Different horn blasts should be used for before the lift, "all clear," and after the lift.

Air horns and audible cues are crucial because not everyone nearby may have a direct line of sight to the crane.

Safety Lights

Proper lighting illuminating the crane and moving parts is vital because it helps distinguish the crane from its surroundings. Natural light varies depending on the time of day and weather conditions, making it difficult to see the crane without adequate lighting.

Warning spotlights can be strategically placed around the crane to alert people traveling within the crane’s vicinity to the equipment and associated risks.

Transporting Cranes

Cranes are large, and often require a separate plan to maneuver and set up at the job site. This is particularly important if the crane needs to navigate through crowded urban areas or complicated industrial job sites.

Study the intended route first and carefully measure its dimensions to ensure the crane can pass safely. Account for additional clearance around turns and complex angles.

Spotters on either side of the crane can be helpful when maneuvering around corners. The driver and spotters should always maintain constant visual or audible contact.

Many cranes require oversized load warnings on the exterior—ensure compliance with all roadway and local laws. This often involves adding bright color flags and signs to the transport vehicle to make it more visible to other drivers. Some oversized loads require pre-clearance or police escorts.

Some cranes may exceed local weight limits—this is especially important to check if your route includes bridges or elevated roads.

Lift Plan

A lift plan is akin to an architectural blueprint for a building—it requires careful thought and design to achieve the desired outcome.

A lift plan is typically created by an engineer with crane experience and includes several job-specific considerations, such as:

• The weight of the load and the crane's lifting capacity
• The location of the load's center of gravity
• The maximum dimensions of the load
• The location and quantity of approved lifting lugs/lifting points
• The rigging gear required for specific lifting points and the center of gravity
• Height restrictions and known obstacles
• Risk assessment and measures to mitigate risks
• Method statement (process, procedure, engineering data, costing, public and site impact, and preparation requirements)

The lift plan should be distributed to all personnel involved with the crane. Since lift plans can change, it’s crucial to redistribute the latest version to all team members to ensure everyone is referencing the same information.

OSHA Crane Safety Hand Signals

Crane operators and signal persons must use specific hand signals to communicate visually with each other. OSHA has established industry guidelines for these signals. Below are the most common crane hand 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 Rentals

Many crane rental companies can provide you with basic safety resources, a list of reputable and licensed crane operators, as well as transportation to and from the job site. Additionally, many crane rental companies can create a lift plan for you or refer you to someone who can. Each job is unique, so it’s important to discuss your needs with your crane rental company first.

Resources

12 Types of Cranes
OSHA Crane, Derrick and Hoist Safety
Crane Safety Video

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