How to safely operate an overhead crane?

Overhead cranes are essential equipment across various industries, used to lift and transport heavy loads. However, their operation involves several risks that may compromise workplace safety and operational efficiency. This article outlines mandatory safety regulations that must be followed during crane operation to minimize accidents, ensure worker safety and protect assets, reduce equipment malfunctions, and extend the crane’s service life.

Why Safety Requirements Matter in Overhead Crane Operation

Common Incidents in Overhead Crane Operations

According to industrial safety data, 73% of crane-related incidents are due to non-compliance with occupational safety protocols, while the remaining 27% result from external factors such as natural disasters, faulty equipment, or substandard working conditions.

Key causes include:

• Inattention or lack of focus during operation, increasing the risk of accidents.
• Operating outside prescribed procedures, ignoring safety rules, or engaging in hazardous behavior.
• Lack of personal protective equipment (PPE) or improper use, leading to severe injuries in case of incidents.
• Operating cranes while fatigued, intoxicated, or unfit for work due to health issues.

Typical incidents resulting from these causes:

• Lifting cable or load hook failure due to overloading beyond permissible limits, causing property damage and endangering operators and nearby workers.
• Excessive brake lining wear, leading to weak braking force and uncontrolled crane movement.
• Cable wear or breakage from prolonged use, poor maintenance, or friction against crane components.
• Loose cable joints causing slippage from pulleys.

Technical Requirements to Ensure Safe Crane Operation

Overhead cranes handle heavy loads in hazardous environments. Adhering to safety standards before and during operation significantly reduces the risk of occupational accidents and material losses.

Critical Components

Wire Ropes

• Select ropes with appropriate tensile strength.
• Ensure hoist ropes are of adequate length, leaving sufficient reserve turns on the drum.
• For slinging ropes, maintain an angle of less than 90 degrees between strands.
• Comply with cable clamp safety standards.
• Frequently inspect rope conditions and retire them per regulatory criteria.

Drums and Pulleys

Replace when cracked or excessively worn beyond allowable standards.

Brakes

Replace if cracked or when the brake lining is worn more than 50% or the drum more than 30% of original thickness.

For the Crane Itself:

• Cranes must be designed, fabricated, installed, and commissioned in compliance with national safety standards.
• Critical parts such as main and end girders, frames, wheels, rails, cables, hooks, hoists, electrical systems, and brakes must be thoroughly inspected before use.
• Equip cranes with essential safety systems, including travel limiters, hazard alarms, and collision prevention mechanisms.
• Ensure regular maintenance and government-certified safety inspections in accordance with manufacturer and labor authority regulations.

For Crane Operators:

• Operators must wear required personal protective equipment and verify load weight does not exceed permissible limits.
• Operators must be proficient in crane components, working principles, safe operation, and possess government-issued certification for crane operation.

Safety Requirements During Overhead Crane Operation

• Warn and restrict unauthorized personnel from entering hazardous zones and ensure the work area is clean and obstacle-free.
• Personnel without responsibilities must not operate the crane under any circumstances.
• Never lift loads that exceed the specified weight limits. Loads must be securely fastened to prevent falling or slipping during transport.
• During operations beneath the crane, workers must maintain a vertical clearance of at least 1.5 meters.
• If any malfunction is detected, stop operations immediately and report to the direct supervisor.
• Safety measures must be in place to eliminate accident risks when using cranes to lift loads across workshops or when using two or more lifting devices for a single load.
• Stop crane operation if there is visible deformation of the metal structure; brake malfunction; excessive wear, cracks, or damage on hooks, cables, pulleys, or drums; or damaged rails.

Safety Requirements After Crane Operation

• Ensure the crane has completely stopped before switching off the power. Remote controls and wired controllers must be stored in a safe, visible, dry, and well-ventilated area.
• Shut off the power, lower the load to a safe position, and lock the brakes.
• Observe the safety inspection schedule of the crane. If safety is compromised, request inspection ahead of schedule.
• Maintenance and storage must follow the manufacturer’s guidelines.

Specific Safety Regulations at THACO INDUSTRIES

For Crane Operators:

• Operators must not suffer from neurological disorders, heart failure, or poor vision (<5/10) to be eligible to use the equipment.
• Operators and workers within the crane’s operating zone must not use mobile phones or perform unrelated tasks. Full PPE must be worn, including uniforms, helmets with chin straps, steel toed boots, and safety harnesses for work above 2 meters. Operators must wear identification armbands or badges.
• Only use equipment that meets technical standards, matches the design specifications, has passed safety inspections, and is still valid.
• Place cranes on firm, stable ground and in accordance with the manufacturer’s specifications. Never overload the crane beyond rated or regulated limits.
• Ensure adequate lighting and safety measures in the lifting and transport zone.
• Assign a minimum of two workers per crane, depending on the working conditions.
• Install safety barriers, warning signs, signals, or fences to protect people, equipment, and materials in the operating zone.

Operational Safety Requirements:

• When lifting or moving loads near equipment or obstacles, no person including riggers should stand between the load and obstacles.
• Loads or crane booms must not be above areas with personnel. Issue warning signals to clear the area before proceeding.
• Pause lifting at 200–300mm to check load stability, lifting mechanisms, and brakes before continuing. When moving horizontally, maintain at least 0.5 meters above the highest obstruction.
• Distribute loads evenly. When loading onto transport vehicles, ensure balance and stability.
• Tension cables evenly and keep them vertical. Minimize load swinging.
• During breaks, raise hooks above all obstacles, maintaining at least 2 meters clearance.

THACO INDUSTRIES Leverages Technology to Improve Crane Operation Safety

THACO INDUSTRIES is a leading industrial corporation in Vietnam, pioneering in the adoption of advanced technologies to enhance product quality and worker safety. In crane operations, THACO INDUSTRIES has implemented modern solutions to improve safety:

• Smart Control Devices: Use of wireless remote controls (radio or infrared) allowing operators to work at a safe distance. Variable frequency drive (VFD) technology enables smooth and precise lifting and traveling, minimizing vibrations and collisions.
• Advanced Monitoring Systems: Sensors and data acquisition units monitor crane activities in real time, detecting overloads, tilt, or instability, and issuing alerts.
• Overload Protection Devices: Automatically cut power when the load exceeds rated capacity, protecting the crane’s components.
• Safety Control Systems: Automatically adjust speed and movement direction for safe operation. These systems decelerate near obstacles or stop upon overload detection.
• Anti-Collision Sensors: Installed around cranes to detect obstacles and warn operators critical in tight or dimly lit environments.
• Safety Braking Systems: Includes primary and secondary brakes, ensuring precise stopping in all conditions.
• Material Innovations in Cables and Chains: Enhances lifting system durability and long-term safety.

Additionally, THACO INDUSTRIES offers scheduled crane maintenance services to ensure optimal performance and protect worker health and safety.

THACO INDUSTRIES – Trusted OEM Manufacturer and Installer of Industrial Cranes in Vietnam

THACO INDUSTRIES (a subsidiary of THACO) is a reputable OEM crane manufacturer in Vietnam. The corporation owns one of the largest mechanical complexes in the country, featuring modern, closed-loop production lines imported from Australia, Switzerland, Japan, and South Korea. Products are manufactured to technical standards with high durability and precision.

All processes are strictly monitored according to ISO 9001:2015 and ISO 14001:2015 quality management systems.

THACO INDUSTRIES offers end-to-end services including consulting, design, fabrication, installation, operation transfer, and maintenance ensuring high-quality, safe, and technically compliant products. With a team of 1,000 skilled engineers and modern design software, THACO INDUSTRIES  delivers tailored solutions for every market.

As a trusted crane supplier in Vietnam, THACO INDUSTRIES is committed to delivering top-tier, safe products. Its adoption of advanced technology keeps the corporation at the forefront of the crane industry, meeting all customer needs.

If you’re seeking a reliable and competitively priced crane manufacturing and installation partner, THACO INDUSTRIES is your ideal choice. For immediate consultation, please contact our hotline: 0348620063.