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                        10 min read

                        The ultimate guide to cranes: usage, safety and best practices

                        The ultimate guide to cranes: usage, safety and best practices

                        Cranes are indispensable machines in numerous industries, playing a critical role in lifting and moving heavy materials. However, their operation carries significant risks, making safety and setting best practice for operation paramount. This guide will cover everything from the basics of crane usage to safety, risk assessments and crane compliance. 

                         

                        In this article: 

                        What is a crane? 

                        Crane components 

                        Industries cranes are used in 

                        Types of cranes 

                        Sizes and classifications of cranes 

                        Attachments for cranes 

                        Popular makes of cranes in Australia  

                        Potential hazards and safety issues relating to cranes  

                        Crane risk assessments  

                        How to ensure crane compliance  

                         

                         

                        What is a crane? 

                        A crane is a machine used for lifting and moving heavy objects. Cranes come in various forms, from small, portable machines to towering structures and are used across a wide range of tasks and industries. 

                         

                        Crane components 

                        Cranes consist of several key components, each playing a specific role in ensuring their functionality and safety. These include: 

                        • Boom: the long arm used for lifting 
                        • Hoist: the mechanism that lifts the load 
                        • Counterweight: balances the load being lifted 
                        • Outriggers: stabilisers used for maintaining balance during operation 
                        • Cab: where the crane operator sits and controls the machine. 

                         

                        Industries cranes are used in 

                        Cranes are used in a wide range of industries. Each industry has its own unique crane requirements based on the specific tasks involved. Some of these industries include: 

                        • Construction: for lifting materials such as steel beams, concrete and equipment 
                        • Mining: used for material transport and infrastructure development 
                        • Shipping and ports: loading and unloading cargo from ships 
                        • Manufacturing: moving heavy equipment and materials across factory floors 
                        • Utilities: installing power lines, wind turbines and other large equipment.  

                         

                        Types of cranes 

                         
                        Tower cranes 

                        Tower cranes are large, fixed cranes commonly seen on vertical construction sites. They provide excellent height and lifting capacity and are anchored to the ground or structures for stability. Tower cranes are commonly used for the construction of skyscrapers, bridges and large-scale infrastructure projects. 

                        Mobile cranes

                        Mounted on trucks or vehicles, mobile cranes are versatile and can be easily transported from one job site to another. These cranes typically feature telescopic booms and outriggers for stability. Mobile cranes are best for short-term construction projects, urban infrastructure and general maintenance work. 

                        Crawler cranes 

                        Crawler cranes are mounted on a set of tracks, which provide stability and mobility over rough or uneven terrain. They are particularly useful on construction sites where the ground is not fully prepared, mining or wind farm installations. 

                        Overhead or bridge cranes 

                        Overhead cranes are typically used in industrial environments such as factories or warehouses. They are mounted on a system of rails fixed to the ceiling, allowing for movement across large work areas. These cranes are best used for indoor material handling, assembly lines and large manufacturing plants. 

                        Gantry cranes 

                        Similar to overhead cranes, gantry cranes are supported by legs and are used for lifting heavy loads, particularly in outdoor settings. These cranes can be either fixed or mobile. Gantry cranes are commonly used in shipbuilding, loading and unloading ships and large construction sites. 

                        Industrial cranes 

                        Industrial cranes are a broad category of cranes specifically designed for indoor use in manufacturing, production, warehouses and maintenance settings. They are typically stationary or mounted on tracks to move along a predetermined path. These cranes are used for precision work, handling heavy machinery, moving materials across production lines or in assembly processes. 

                        Floating cranes 

                        Floating cranes are mounted on barges or other waterborne platforms and are used in offshore construction or in ports for loading and unloading ships. They are mostly used in dock work, marine construction and offshore wind farms. 

                        Railroad cranes 

                        Specifically designed to operate on railway tracks, these cranes are often used for railway construction and maintenance tasks, such as lifting damaged railcars or laying tracks. 

                        Rough terrain cranes 

                        These mobile cranes are designed for use on rough, uneven surfaces. They are equipped with large, rugged tires and outriggers for stabilisation. These cranes are mostly used for construction in off-road or undeveloped areas, oil and gas fields and remote utility projects. 

                        Telescopic cranes 

                        Telescopic cranes feature a boom that can extend and retract through a series of tubes for reach and height versatility. They are commonly used for short-term construction, transport tasks and rescue operations where precise placement of loads is required. 

                        Loader or knuckle boom cranes 

                        Loader cranes, as the name suggests, are used for loading and unloading goods. These are compact, folding cranes often mounted on trucks and can be folded down when not in use. 

                        Lattice boom cranes 

                        Lattice boom cranes have a lattice structure to reduce weight while maintaining strength and stability. These are commonly used for heavy lifting in large-scale projects such as those on large construction sites, infrastructure projects and mines. 

                        All-terrain cranes 

                        These cranes are a hybrid between rough terrain and mobile cranes. They are capable of navigating both paved roads and rough terrain, offering versatility for a range of projects. They are best for construction sites with varied terrain as well as long-distance transport between sites. 

                        Aerial or helicopter cranes 

                        Aerial cranes use helicopters to lift loads in remote or difficult-to-access areas. They are typically used for installing transmission towers, placing large air conditioning units, transporting materials in mountainous areas and even disaster relief. 

                         

                        Sizes and classifications of cranes 

                        Cranes are classified based on their size, lifting capacity and mobility. Common size classifications include: 

                        • Small cranes: typically mobile, used for light construction and quick jobs 
                        • Medium cranes: versatile, with a higher lifting capacity for standard construction and industrial jobs 
                        • Heavy-duty cranes: stationary or mobile, used for large-scale construction, infrastructure projects and shipping 

                         

                        Attachments for cranes 

                        Crane attachments enhance functionality, efficiency and safety. Common attachments include: 

                        • Hooks: standard attachment for lifting 
                        • Clamps: used for gripping specific types of materials 
                        • Buckets: ideal for lifting loose materials like dirt or gravel 
                        • Magnets: useful for lifting metallic items 
                        • Boom extensions: extend the reach of the crane for higher elevations 

                         

                        Popular makes of cranes in Australia  

                        There are several manufacturers and models of cranes that are popular in Australia, including: 

                        • Liebherr: known for heavy-duty, reliable construction cranes  
                        • Kobelco: specialising in crawler cranes for tough terrains  
                        • Terex: offers a wide range of mobile and tower cranes  
                        • Manitowoc: well-regarded for high-quality mobile cranes  
                        • Zoomlion: a leader in tower and construction cranes  

                         

                        Potential hazards and safety issues relating to cranes  

                        Crane operation is inherently high-risk and understanding potential hazards is crucial for maintaining people safety. Below are descriptions of the most common crane-related hazards. 

                        Overloading 

                        Overloading occurs when a crane lifts a load that exceeds its rated capacity. This not only puts excessive stress on the crane’s structural components, such as the boom and hoist cables, but also increases the risk of tipping or collapse. Overloading can be prevented by ensuring operators adhere strictly to load charts and use load moment indicators (LMIs) that signal when the crane is approaching its limit. Even partial overloading can have catastrophic consequences, therefore load calculations must include the weight of the load itself, rigging hardware and any environmental factors such as wind resistance. 

                        Unstable ground 

                        Cranes require stable ground to remain balanced during lifting operations. Uneven, soft or sloped ground increases the risk of tipping or destabilising the crane, especially when heavy loads are involved or the boom is extended. Site evaluations should be conducted before crane setup to assess ground conditions. Outriggers or stabilisers must be fully deployed and set on firm, level ground. In some cases, crane mats or steel plates can be used to distribute the crane’s weight more evenly across soft surfaces. 

                        Swinging, unsecured or falling loads 

                        Loads that are improperly rigged or unsecured can swing uncontrollably during a lift, particularly if there are sudden wind gusts or if the load shifts unexpectedly. This can cause damage to structures or nearby equipment, injure workers or destabilise the crane. Using tag lines to control the load’s movement and ensuring proper rigging techniques are followed can prevent such incidents. Additionally, loads must be secured with high-quality slings, hooks and shackles to prevent or falling. 

                        Weather conditions 

                        Weather is a critical factor that can significantly impact crane operations. High winds can cause loads to swing or make the crane’s boom unstable, increasing the risk of tipping or boom collapse. Rain can make the ground slippery, reducing traction and stability. Visibility issues caused by fog or rain can also lead to operator errors. Cranes should not operate during severe weather conditions, especially when wind speeds exceed the crane’s operational limits. Wind speed sensors can help monitor real-time conditions and ensure safe operation however stopping work during adverse conditions is often the best safety measure. 

                        Electrical hazards 

                        Cranes frequently operate near powerlines, making electrical hazards one of the leading causes of fatalities in crane operations. Contact between the crane’s boom or load and live electrical wires can result in electrocution for the operator or workers nearby. Safe approach distances must be maintained at all times and spotters should be used when working in areas with overhead power lines. In some cases, shutting down power in the area may be necessary and insulated links or anti-electrocution devices can provide additional protection. For more information about working near powerlines, check out our articles Managing the risk of working near powerlines and Plant and powerlines.

                         

                        Mechanical failures 

                        Cranes are complex machines with many moving parts, including hydraulic systems, hoist mechanisms and boom sections. Over time, wear and tear can lead to component failures, such as a broken hoist cable or malfunctioning brakes, which can cause sudden load drops or the inability to control the crane properly. Regular and thorough maintenance is essential to avoid these risks. Operators should perform daily pre starts and regular risk assessments should be conducted by qualified personnel to identify and fix potential problems before they worsen or cause an incident. 

                        Falling objects 

                        Any object falling from height, whether it's the load being lifted or components and materials from the crane itself, can result in severe injuries or fatalities for workers below. Exclusion zones should be established to keep unauthorised personnel away from lifting operations and to ensure any falling objects do not strike a person. Additionally, securing tools and materials used in the crane’s cab or boom area is critical to preventing them from falling unexpectedly. 

                        Human error 

                        Human error is a contributing factor in many crane incidents which can often be due to inadequate training, lack of experience or simple oversight. Crane operators must undergo rigorous training to earn certification and should regularly participate in refresher courses to stay up to date on safety protocols and equipment technology. Fatigue, stress or poor judgment can also result in operational mistakes, such as improper rigging or exceeding the crane’s limits. Establishing clear communication protocols, strict training procedures and maintaining high safety standards can minimise these risks. 

                        Crane or boom collapse 

                        Crane collapses can occur due to structural failure, poor maintenance or overloading. Even minor cracks or stress fractures in the boom can lead to a catastrophic collapse if not identified and repaired. Regular inspections of the crane’s structure, particularly the boom and its connections, are vital for preventing such incidents. Additionally, ensuring that the crane is never overloaded or operated outside its design limits is key to avoiding collapse. 

                        Tip over 

                        A crane tipping over often results from unstable ground, improper use of outriggers or attempting to lift loads that are too heavy or positioned too far from the crane’s centre of gravity. To prevent tip overs, it is crucial to ensure the crane is correctly set up on level ground, with outriggers fully extended. Load charts should always be followed and operators should be aware of factors that could shift the crane’s centre of gravity such as extended booms or heavy loads on uneven terrain. 

                         

                        Crane risk assessments  

                        Conducting a comprehensive risk assessment is essential for ensuring crane safety. These assessments are aimed at identifying hazards, evaluating risks and implementing control measures to minimise the likelihood of incidents. Key elements of a crane risk assessment include: 

                        Site evaluation 

                        A thorough evaluation of the worksite is crucial to identifying potential hazards such as soft ground, slopes, overhead power lines or confined spaces. This evaluation ensures the crane is suited to the environment and that any necessary precautions are taken. 

                        Crane selection 

                        Choosing the right crane for the job is an important part of the risk assessment process. Factors like load capacity, boom length and mobility must be considered. For example, if the ground conditions are soft, a crawler crane with a wide base might be more appropriate than a mobile crane with tyres. 

                        Load calculations 

                        Properly calculating the weight and balance of the load is critical. Overloading is one of the most common causes of crane incidents, so it's essential to ensure the load does not exceed the crane’s rated capacity. Factors such as wind resistance, load weight distribution and lifting height should all be considered. 

                        Control measures 

                        Based on the identified risks, control measures are implemented to mitigate hazards. These may include setting up exclusion zones to keep workers away from the crane's operational area, using spotters to assist operators and installing mechanical safeguards like load moment indicators. 

                        Personnel training 

                        Ensuring operators and workers are properly trained in crane operations, including how to use safety equipment and emergency response procedures, is critical. Risk assessments should also evaluate the level of experience and certification required for the job. 

                        Emergency preparedness 

                        Risk assessments should include emergency preparedness plans for crane operations. This includes protocols for evacuating the area in the event of a crane collapse or failure as well as procedures for managing incidents like falling loads or electrocution. 

                         

                        How to ensure crane compliance  

                        Ensuring compliance with regulatory standards is vital for legal, safety and operational purposes. Ensuring compliance not only helps avoid fines and legal repercussions but also reduces the risk of incidents, therefore protecting both workers and assets. Crane compliance refers to meeting all the relevant legal requirements, industry standards and best practices associated with crane operations. In Australia, this primarily involves adherence to work health and safety (WHS) regulations and legislation as well as Australian standards including AS 2550 (Safe Use of Cranes) and AS 1418 (Design of Cranes). 

                        Conduct regular inspections and maintenance 

                        Cranes must undergo regular inspections by certified professionals. Australian regulations require annual major inspections, as well as routine inspections based on the usage of the crane. Inspections should focus on: 

                        • Structural components such as booms and joints 
                        • Hoist and wire rope condition 
                        • Hydraulic and electrical systems 
                        • Safety devices such as load limiters and anti-collision systems 
                        Ensure crane operators are certified  

                        Only licensed and qualified personnel should operate cranes. In Australia, crane operators are required to hold a high risk work (HRW) licence and complete regular training updates. This ensures operators are proficient with new technologies and safety protocols. 

                        Load testing 

                        Cranes must be load tested regularly to ensure they can safely handle their rated capacities. These tests should be performed under controlled conditions and documented as part of the crane’s maintenance records. Load testing is critical after major repairs or modifications to the crane. 

                        Documentation and record keeping 

                        Keeping comprehensive records of crane operations, inspections and maintenance is crucial for compliance. Documentation should include: 

                        • Inspection reports 
                        • Maintenance logs 
                        • Load test results 
                        • Operator certifications 
                        • Risk assessment reports 
                        Compliance with Australian standards (AS 2550 and AS 1418) 

                        These standards provide detailed guidelines on crane operation, maintenance and safety. Compliance with AS 2550 ensures cranes are used in accordance with best practices, while AS 1418 governs the design and construction of cranes. Adhering to these standards is not only a legal requirement but also a critical step toward ensuring the safety of crane operations. 

                        Machinery safety systems 

                        Implementing a robust machinery safety system is key to ensuring all crane operations comply with legal requirements and safety standards. This system should cover everything from risk assessments and daily pre starts to safety information sharing and service scheduling. To find out more about machinery safety systems, check out our guide Fill the gaps in your machinery safety systems.  

                         

                         

                        Want to learn more about keeping your crane safe and compliant? 

                        Ideagen Plant Assessor is here to help! Chat with our team on machinery compliance experts by phoning 1300 728 852 or emailing info@assessor.com.au. 

                        Disclaimer: This information is intended to provide general information on the subject matter. This is not intended as legal or expert advice for your specific situation. You should seek professional advice before acting or relying on the content of this information. 


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                        About the Author

                        Matt Ireland is the Technical Compliance Manager at Ideagen Plant Assessor. His expertise and knowledge of machinery compliance stems from a broad range of experience in the construction industry. He has also personally inspected and completed over 15,000 machinery risk assessments as a Field Officer in our Professional Services Team. Matt’s integral role involves taking technical documents such as Australian standards and legislation, interpreting them and translating them into the IP that makes the Ideagen Plant Assessor software unique. Read More.

                         

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