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Authorized By:

Title: Safe Work Practices &

Procedure Overhead Crane Operation Approved By:

Issue Date: Risk Level: HIGH Page Number: 1 of 10

DO NOT use this machine/equipment unless you have been

trained in its safe use and are deemed a competent operator!
An overhead crane, commonly called a bridge crane, is a type of crane
found in industrial environments. An overhead crane consists of parallel
Description of Work:
runways with a traveling bridge spanning the gap. A hoist, the lifting
component of a crane, travels along the bridge.
*This information does not take precedence over Saskatchewan Employment Act and the Occupational
Health & Safety Regulations.
Potential Hazards:
 Electrical
 Falling Materials
 Overloading
 Pinch Points
 High Sound Levels
 Head and/or body Injury
 Death

Personal Protective Equipment (PPE) Required (Check the box for required PPE):

Gloves Face Masks Eye Welding Appropriate Hearing Protective

Protection Mask Footwear Protection Clothing

Other PPE: Hard Hat

Competent Worker- For cranes and hoists under 5 tonnes requires only that the operator be a competent
worker which is defined as follows in Saskatchewan OH&S Regulations: “with respect to a particular task or
duty, includes a worker who is being trained to perform that task or carry out that duty and who is under
close and competent supervision during that training”
Training and protocols must comply with Saskatchewan OH&S Regulations as well as adequate records are
kept on file.

Safe Work Procedure Checklist:

1. General Safeguards:
a. Inspect overhead crane daily. Report all malfunctions to the designated authority. Do not
operate any unsafe overhead cranes.
b. Report accidents/incidents and near misses immediately to the supervisor so they can be
investigated.
c. Always ensure the lifting device and all supporting components are rated for the load to be
lifted.
d. Never allow a co-worker between a fixed object and a load.
e. Always position lifting device directly over load before lifting.
f. Always ensure that you know the safe travel radius of the crane. Contact with electrical
sources or other hazards can result in catastrophic consequences.
g. Always ensure energy sources are dissipated before initiating any maintenance activity.
 INSERT LOGO No.
Authorized By:

Title: Safe Work Practices &

Procedure Overhead Crane Operation Approved By:

Issue Date: Risk Level: HIGH Page Number: 2 of 10

2. PRE-Operation Checks:
i. The Hook (look for cracks, gouges, excessive wear and correctly operating latch)
ii. The Block (check that block is level and free from damage, wear or looseness in
assembly or fittings)
iii. Crane Chain
a. Elongation of links
b. Deformation of links
c. Cuts, dents or gouges
d. Cracks
e. Excessive wear
f. Excessive corrosion
g. Twists
iv. Crane Wire Rope
a. Kinks
b. Twists
c. Bird caging
d. Broken Wires
e. Excessive rust or corrosion
f. Excessive wear or abrasion
v. Nylon Web Slings
a. Excessive wear or abrasion
b. Cut/penetration exceeding 15% of width
c. Manufacturer’s label
d. Load rating label
e. Wrap thread damage
f. Broken or worn stitches of load bearing splices
g. End fittings are excessively pitted or corroded
vi. Safe Work Load - Ensure it is visible on crane and all lifting gear
vii. Controls - Ensure all buttons are operational; check multiple speeds and emergency
stop, and buttons are clearly labeled
*this is not a complete list, please refer to OHS Overhead Crane Policy for more information
3. Pre-Lift Planning:
a. Does this qualify as a Critical Lift? (see Critical Lift bellow)
b. Inspect where it is going (landing point)?
 Is the area clear and ready for the load?
 Is there any stored material that might get knocked over by the load?
 Are other workers near the landing point ready to receive the load?
c. Plan and inspect travel route:
 Is it clear?
 Are there obstructions?
 Are there workers in the way?
 How the load will be stabilized during travel?
4. Before using an Overhead Crane:
You must confirm the manufacturer’s limits. A crane should never be taken beyond the
manufacturer’s limits, as these are set with the safety of the operator in mind. Any lift that
approaches these limits must be undertaken with much more caution with significant planning and
preparation. The capacity of the crane must be marked on the bridge and trolley.
5. Calculating the Weight of an Object:
 You need to know the weight of the load so that you can use the right capacity crane and rigging to
complete the lift.
 It is important to remember that anything added to the hook is considered part of the load and
must be added to the overall weight of the load.
 Overloading any component of a crane (sling, hook, hoist, etc.) can damage the crane or rigging and
may result in a serious accident
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Title: Safe Work Practices &

Procedure Overhead Crane Operation Approved By:

Issue Date: Risk Level: HIGH Page Number: 3 of 10

 You can find the weight of an object by:

o Check with experienced
workers o Check bills of lading
o Check drawing or blueprints
o Calculation (for items such as length of pipe, beam or steel plate, it may be possible to
calculate the weight if you know the weight per unit of the length, area, or volume)
o Charts and tables (some facilities there are weights, charts or tables written for common
materials)
o Scales (use of scales is recommended on all loads approaching the limits of the crane.
There are many devices available that attach between the crane hook and the load.
6. Critical Lifting:
a. A critical lift is defined as one where the gross load exceeds 75% of the crane’s maximum
capacity.
b. Before a Critical Lift can be performed there must be a written operating procedure that
details the steps in making the lift. Also, it must have management approval and a brief
safety meeting to discuss the procedure must be held prior to the lift.
7. Rigging Planning:
a. Who will select the appropriate rigging?
 Will the crane operator determine the load weight, lift points and rigging to be used?
 Will others attach the rigging, are they properly trained, and do they understand the
details of the lift plan and all pertinent information.
b. Has the rigging equipment been inspected?
 Is it confirmed to be in good condition?
 Are capacity tags legible and is the rigging of sufficient capacity in the hitch to be
used for the lift to be made?
c. What is the weight of the load?
 How was the load weight determined?
 Add the weight of all rigging to the load weight to determine total weight to be lifted?
d. Has the center of gravity been confirmed?
 Is it marked on the load?
 Is everyone aware that the load may shift slightly when lifted?
e. Has rigging been protected from damage?
 Are softeners, sleeves or other protectors available?
 Is there a risk of damage to the load?
 What steps must be taken to protect the load from the rigging?
 Are there any special circumstances that must be addressed?
8. Types of Rigging:
a. Slings and Attachments - A range of different rigging slings and attachments is used
depending on the load shape, size, weight and material. These can include:
 Wire Rope Sling – is made of wire rope, fitted with eyes at both ends. It must have a tag
on it that indicates the lifting capacity of the sling.
 Web Sling – made out of a length of nylon fibre fitted with eyes or brackets at either end
or a polyester round sling.
 Chain Sling – is a length of chain with eye, hooks or shackles attached to both ends.
Can also be manufactured as two-legged chain slings. In these arrangements, one end
of the chain is attached to a lifting ring and the free ends are equipped with hooks. Must
be grade 8 chain.
 Spreader Bar - is a length of metal beam that is attached to the crane hook.
 Lifting Beam – is a large version of a spreader bar. These rigging devices are extremely
valuable when using an overhead crane, because of clearance is always an issue. This
tool can easily use short slings to raise a load when greater clearance is required.
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Title: Safe Work Practices &

Procedure Overhead Crane Operation Approved By:

Issue Date: Risk Level: HIGH Page Number: 4 of 10

 Equalizer Beam – can be used when the load is unevenly balance.

Wire Rope Sling Web Sling Chain Sling Spreader/Lifting Beam

a. Hooks – are used in combination with slings and chokers in complex rigging situations.
Hooks that are connected to any type of rigging, such as a shackle, will require a
safety latch. Hooks come in a variety of styles to suit different tasks, some include:
 Grab Hooks – Designed to catch the links of the chain.
 Slide Hook – used to choke a chain sling
 Sorting Hook – Used to move material such as pipe by inserting it directly into the
open end of the pipe.

b. Clamps – in metal fabricating, a common type of clamp is a plate

clamp. This clamp is designed to grip the edges of metal plate for
hoisting.
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Procedure Overhead Crane Operation Approved By:

Issue Date: Risk Level: HIGH Page Number: 5 of 10

c. Shackles – fittings that are used to link slings together in various combinations for special
lifts. They come in a variety of styles, but the three most common are:
 Round Pin Shackles – can only be used when the load is applied in a straight line
and there is no chance of it rolling onto its side.
 Screw Pin Shackles – can be used to gather slings together for a lift. Always be
sure that the pin is tight and the load will have no chance of rotating it.
 Bolt Type Shackles – are usually used in permanent applications or in situations
where the load may slide on the pin.

d. Eyebolts – is a threaded metal bolt with an eye at one end. The bolt is attached to the load
and the eye provides a point for attaching a sling using a hook or shackle. Eye bolts come in
three styles, shouldered, non-shouldered and machinery. If an eye bolt must be used at an
angle, only the shouldered type should be used, and the eye must be in line with the
direction of pull. Slings must never be reeved through one eyebolt to another, as the stress
on the rigging will be too great.
 If side loading is necessary, it is better choice to use a swivel. Swivels are
designed to be used in angular pull stations without any loss of Safe Work Load
(SWL)
 A lifting lug is a hook-up point manufactured on a piece of equipment. Do not use
anything but the original lug designed for lifting purposes. Weld on lifting lugs can
only be used once and are not to be re-used after being cut off.
e. Tag Line – is a length of fibre rope that is attached to the load. It allows a worker who is
assisting the crane operator to maintain control and guide the load. Using a tag line lets the
assistant control the load when it is at a height or distance beyond the workers reach.
When using a tag line, do not stand under the load; position yourself on the back end of the
load, making sure you have clear visibility of any obstructions while walking with the load.
Never wrap the tag line around your hand or any part of your body as serious injury could
result. Remember tag lines will conduct electricity.
f. Softener – Protects the rigging equipment against cutting and fraying
g. Sling Covers – a nylon or leather cover that is designed to be placed over the sling.
h. Turnbuckles – is used when adjustments need to be made to sling leg length due to an
odd shaped load. They should be weldless alloy and tightened to the same torque as
bolts of equal size. Where there is a danger of loosening from motion or vibration,
turnbuckles should be wired to the end fitting and the body. Jam nuts should not be used
because they overstress the screw thread. Rod and body size should always match.
i. Basic Hitches – Hitches is the technique that uses a sling to attach a load to the crane
hook. There are three basic hitches; the Vertical Hitch, Choker Hitch, and the Basket
Hitch.
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Title: Safe Work Practices &

Procedure Overhead Crane Operation Approved By:

Issue Date: Risk Level: HIGH Page Number: 6 of 10

j. Complex Hitches – There are three complex hitches; Brindle Hitch, Turning Hitch,
and the Adjustable Hitches.

Turn Hitch

Some chain bridles will come Web Sling Adjustable Hitch

with two shorter chains equipped
with grab hooks to shorten one leg.

9. Choosing Rigging Based on the Load:

a. The type of rigging you use is based on:
 The Size of the load determines how many slings you need and how long the slings
need to be.
 The Shape of the load determines how many hitches you should use, where you
place them, and what attachments you may have to use.
 The Weight of the load determines the capacity of slings and attachments to ensure the
entire rigging system is strong enough to lift the weight.
b. Never wrap the crane hook around the load. Attach the load to the crane hook by slings or
other rigging devices.
10. Load Control:
Different hitches provide certain levels of control over the load they are attached to. This can be a
critical factor when determining how to rig the load.
a. Single Leg – the single leg sling used in a vertical hitch provides good load control if the load is
small or compact. This hitch must be attached directly above the center of gravity. If the sling is
used in chocker, the level of control does not improve.
b. Basket Hitch – the basket hitch provides good control over loads that are adequately held in the
basket. This hitch should not be used for loads that are loose unless they are used in tandem.
c. Double wrap – can be sued in a choker or basket hitch and it provides very good control
over loose or slippery loads.
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Title: Safe Work Practices &

Procedure Overhead Crane Operation Approved By:

Issue Date: Risk Level: HIGH Page Number: 7 of 10

d. Multiple Leg – the use of more than one sling leg can dramatically improve the amount of control
that the operator has over the load. Two, three or four leg bridles will give excellent control over
the load but may not increase the lifting capacity due to the angle of the slings. Another item to
consider is the fact that the load may not be evenly distributed to all the sling legs. Always use
caution when determining the capacity of slings used in this situation and ensure that only two of
the legs should be able to hold the load.
11. Calculating the Center of Gravity:
 The center of gravity is the point around which an object weight is evenly balanced.
 To make a level or stable lift, the crane hook or block must be directly above the center of
gravity.
 The center of gravity must also be below the lowest sling attachment point before the load is
lifted.
 The center of gravity may be difficult to determine, especially if the load is not symmetrical. If you
are unsure of the center of gravity, it can be established through trial and error. Attach the rigging to
the load, estimating the center of gravity and take some of the weight. If your crane hook is not
directly above the center of gravity, the object will begin to shift to one side or the other. Adjust your
slings, moving them in the opposite direction of the slide and try the lift again. Continue this process
until the object lifts evenly.
12. Sling Angles:
All slings must have a marking that identifies their safe working load. As was mentioned, this is the
maximum amount of stress that should be applied to a sling. When slings are used at an angle, the amount
of stress applied to them increases. This is because force is being applied in two different directions:
downward by the weight of the load, and sideways because the slings naturally want to hang vertically. This
increase in stress is often not realized by the individual hooking up the load.

As the angle of the sling decreases, the amount of stress on that sling increases. At a 60° angle, the
load on a single sling leg is 115% of the load weight. When the angle drops to 45° the load increases to
140% of the load weight, and at 30° the load increases to 200% of the load weight.

a) Use sling length and distance from the hook to the load.

Load on each sling leg = load (W) x sling length (L)

2 x height to hook (H)
On “basket” hitches, use the “effective” length of the sling which is the sling from the hook to
contact with load. “Height” is the vertical distance from the hook to the sling contact point with load.
b) Use sling length and distance between pick-up points.
1) Divide S x L to get A.
2) Find A in table. If not the same, use the next highest number.
3) Select number beside it on column B.
4) Multiply the weight of the load by B to get the load on each sling.
c) Use sling angle to the load.
1) Select known sling angle form column C.
2) Select number beside it in column B.
3) Multiply the weight of the load by B to get the load on each sling.
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Procedure Overhead Crane Operation Approved By:

Issue Date: Risk Level: HIGH Page Number: 8 of 10

d) For unequal sling lengths, calculate each sling separately.

Sling angle is the “inside” angle. A and B are the “outside” angles for slings to 90o verticals from the
load.

i. Determine angles A and B. Example: A = 90o – sling angle

B = 90o – sling angle
ii. Select sine for angles A and B from chart.

iii. Select sine for angle C from chart, where Angle C = 180o–
(angles A +B)
Calculate load on each sling separately using sine values for
angles A, B and C.

Example: load on left sling = W x sine (A)

Sine (C)

load on left sling = W x sine (A)

sine (C)
e) Recommended Safe Listing Angle - The minimum recommended SAFE lifting angle for sling
legs is 60º. The 60º angle is easily determined by using the actual sling for measuring. Lifting at
60º angle creates an equilateral triangle, where all three sides are the same length. Once the
centre of the load is determined, the sling is laid across the load and the two ends are marked as
pickup points.

60°
16
feet 16 feet

60° 60°

16 Feet
Use your sling to determine minimum safe lifting
points
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Title: Safe Work Practices &

Procedure Overhead Crane Operation Approved By:

Issue Date: Risk Level: HIGH Page Number: 9 of 10

13. Lift Execution:

Suspended loads are dangerous. Once lifted the load must be controlled at all times until it is set down
again.
 Stabilize the load – to prevent it from swinging or turning during the lift. Be prepared for unexpected
wind gusts from an open door
 Never work under a suspended load - In spite of diligent application of controls, equipment may
fail and loads may fall onto the crew below. For this reason, it is both dangerous and illegal to
work under a suspended load.
 Never leave a suspended load unattended – If you must leave before completing the lift, lower
the load to the floor or place it on stands to ensure it cannot fall.
 Never lift a load over a worker – Ensure the path is clear and use guards or barriers if necessary,
to keep workers away.
14. Signalers:
Signalers are required whenever the operator cannot see the load, the landing area or the full path of travel
of the load or crane. They are also needed when the load is too far from the operator for distances to be
accurately judged. Signalers must know the hand signals for hoisting operations.

Workers should not perform other work while acting as signalers. They must be in clear view of the
operator, and the intended path of the machine and the load. At the same time, they must remain clear of
this path. Special attention should be given to any part of the operation, which the crane operator cannot
see.
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Title: Safe Work Practices &

Procedure Overhead Crane Operation Approved By:

Issue Date: Risk Level: HIGH Page Number: 10 of 10

15. Emergency Procedures:

Even with well-maintained equipment and properly trained operators, problems can still occur during a lift.
The key to dealing with any problem or emergency situation is to protect yourself and others around you.
Some examples of emergency situations are as follows.
 Runaways
 Frozen controls
 Brake failure
 Electrical malfunction
 Derailment
 Rigging failure

If at any time you must deal with an emergency situation there are 3 steps to take:
i. Barricade the Area – the intent of this step is to keep everyone out of harm’s way. This may be as
simple as having someone watch the area while the operator shuts off the power.
ii. Shut off the Power – the intent of this step is to interrupt power at the main breaker, not just at the
pendant.
iii. Contact your Supervisor – when you are sure that there is no immediate danger, find your
supervisor and inform him/her of the problem.
16. Standard Shutdown Procedure:
i. Lower any raised load to ground level. Chock load if necessary.
ii. Disconnect hook from the load.
iii. Remove all lifting gear from the load. (Slings, shackles etc.)
iv. Raise crane hook up to almost maximum height. This protects chain/rope from corrosion
v. Locate the crane to a safe position – to the far end of a building is the preferred position.
vi. Ensure the pendant/remote is in the OFF position and placed in a designated area.
vii. Turn power off at the main isolation switch.
viii. Lifting gear should be checked before placed in storage, any defects shall be reported to the
Tool Room attendant.
ix. Place all lifting gear in a designated area.
17. Repairs and Maintenance:
Report all malfunctions or maintenance issues to your supervisor immediately.

When a crane is in need of repairs it will typically require the knowledge of a professional, depending on the
seriousness of the problem. Consulting the owner’s manual will help you decide whether or not you can
make the repair in house.

Any work done to “critical components” or load bearing structure will require the direction of
a professional engineer.

The manual for your crane is a very valuable tool. It will not only tell you what repairs can be made in house,
but it will likely give you a maintenance schedule as well. It should also contain all of the original
specifications of your crane’s equipment (hooks, wire rope, sheaves etc.).
Before repairs or maintenance are placed in action lockout/tag out procedure must be in place.
Please refer to Lockout/Tag out Policy.
Forms Associated with this Policy

 INSERT APPLICABLE OHS LEGISLATION HERE IF REQUIRED