Crane Operations Risk Assessment

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This risk assessment covers all crane operations, including but not limited to lifting, lowering, and moving materials and equipment, assembly/disassembly, inspections, and maintenance activities. It includes all types of cranes such as mobile cranes, overhead cranes, and tower cranes. The scope excludes cranes mounted on vehicles and used exclusively for loading/unloading that vehicle.

2. Risk Assessment Methodology

This risk assessment uses a 5x5 risk matrix to determine risk ratings. The hierarchy of controls will be applied to mitigate identified hazards, prioritizing elimination and substitution where feasible, followed by engineering controls, administrative controls, and finally, personal protective equipment (PPE).

3. Risk Matrix Reference

The following matrix is used to evaluate risk levels based on likelihood and severity:

		Likelihood
Rare	Unlikely	Possible	Likely	Almost Certain
Severity	Catastrophic	Low	Low	Medium	High	Extreme
Major	Low	Medium	Medium	High	High
Moderate	Low	Low	Medium	High	High
Minor	Low	Low	Medium	Medium	High
Negligible	Low	Low	Low	Medium	Medium

4. Hazard Identification and Risk Evaluation

1. Contact with power lines during crane operation.

Potential Consequences: Electrocution, severe burns, equipment damage, and power outages.

Affected Persons: Crane operator, riggers, ground personnel, and nearby workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Ensure operators are trained to identify and avoid power lines.
• Maintain a safe distance from power lines as specified by regulations.
• Use proximity warning devices or insulated links when working near power lines.
• Designate a spotter to monitor clearance from power lines.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

2. Overloading the crane beyond its rated capacity.

Potential Consequences: Crane collapse, dropped load, equipment damage, and serious injury or fatality.

Affected Persons: Crane operator, riggers, and ground personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Verify the weight of the load and rigging prior to initiating the lift.
• Use load charts to ensure the crane is not overloaded.
• Inspect rigging and lifting gear before each use.
• Use proper rigging techniques to distribute the load evenly.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

3. Mechanical failure of crane components (e.g., brakes, cables, or controls).

Potential Consequences: Dropped load, uncontrolled crane movement, equipment damage, and potential injuries.

Affected Persons: Crane operator and ground personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

Control Measures

• Implement a preventative maintenance program.
• Conduct pre-shift inspections of crane components, including brakes, cables, and controls.
• Replace worn or damaged parts immediately.
• Ensure that the crane has an operable over-travel limit switch in the hoisting direction.
• Ensure that the crane is equipped with an operable brake.
• Ensure that the crane has a positive mechanical restraint to secure the crane against wind movement while parked.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Moderate	Low

4. Struck-by or crushed-by moving crane components or loads.

Potential Consequences: Serious injury or fatality due to impact or crushing. [2] [2]

Affected Persons: Ground personnel and operators

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Establish and enforce exclusion zones around the crane's working area.
• Use barriers, warning lines, and signage to delineate hazard areas.
• Train employees to recognize struck-by and pinch/crush hazard areas posed by the rotating superstructure.
• Erect and maintain control lines, warning lines, railings or similar barriers to mark the boundaries of the hazard areas.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

5. Communication breakdown between the operator and ground personnel.

Potential Consequences: Miscommunication leading to unsafe crane movements, dropped loads, and potential injuries. [2] [2]

Affected Persons: Crane operator, riggers, and ground personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Ensure proper communication protocols are in place, including hand signals or radio communication.
• Use a designated signal person when the operator's view is obstructed.
• Before an employee goes to a location in the hazard area that is out of view of the operator, the employee (or someone instructed by the employee) must ensure that the operator is informed that he/she is going to that location.
• Where the operator knows that an employee went to a location covered by paragraph (a)(1) [Swing Radius Hazards] of this section, the operator must not rotate the superstructure until the operator is informed in accordance with a pre-arranged system of communication that the employee is in a safe position.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

6. Wire rope failure due to wear, damage, or improper use.

Potential Consequences: Dropped load, equipment damage, and potential injuries. [1] [4]

Affected Persons: Crane operator and ground personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

Control Measures

• Inspect the crane's wire ropes frequently and periodically as described in Table 3.
• Replace wire ropes that are damaged or worn.
• Ensure that the load is not lowered below a level that corresponds to less than two full wraps of wire rope left on the drum.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Moderate	Low

7. Crane instability due to uneven ground or improper setup.

Potential Consequences: Crane tip-over, dropped load, equipment damage, and potential injuries. [3] [6]

Affected Persons: Crane operator and ground personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	Medium

Control Measures

• Ensure that the crane is set up on a stable and level surface.
• Use outriggers or stabilizers according to manufacturer's specifications.
• Take into account ground conditions, gradients, stabilizers, tire pressure and blocking under outriggers.
• Know how to properly use outriggers and stabilizers in accordance with manufacturer specifications.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Low

8. Uncontrolled load movement (swinging, sudden drops).

Potential Consequences: Load striking workers or objects, causing injury or damage. [4]

Affected Persons: Crane operator and nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Provide training on proper lifting techniques and load control.
• Use tag lines to control the load and prevent swinging.
• Make sure that nothing obstructs the movement of a load.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

9. Two-blocking (load block contacting the boom tip).

Potential Consequences: Damage to the crane, dropped load, and potential injuries. [7] [7]

Affected Persons: Crane operator

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

Control Measures

• Ensure that the crane is equipped with a functional anti-two-blocking device.
• Clearly mark the cable at a point that will give the operator sufficient time to stop the hoist to prevent two-blocking, and use a spotter when extending the boom.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Minor	Low

10. Uncontrolled release of energy during maintenance or repairs.

Potential Consequences: Serious injury or fatality to maintenance personnel. [9]

Affected Persons: Crane operator and maintenance personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

Control Measures

• Implement a lockout/tagout procedure for crane maintenance and repairs.
• Ensure that the crane is equipped with a main switch which can be locked out.
• An employer shall establish a written lockout procedure which shall be used in connection with R 408.11872 and R 408.11875. Lockout shall conform to the requirements prescribed in General Industry Safety Standard Part 85 "The Control of Hazardous Energy Sources, (Lockout/Tagout)," as referenced in R 408.11807.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Moderate	Low

5. General Control Measures

• Conduct regular inspections of cranes and lifting equipment, including frequent and periodic mandatory inspection checklist items such as control panels, radio/manual switch, receiver antenna, transmitter functions, transmitter emergency stop, upper sheave(s), wire rope, bottom block assembly, hook & latch, and equalizer sheave.

Use a documented checklist and maintain records of inspections. [1]

• Ensure that only trained and qualified personnel are authorized to operate cranes.

Verify operator qualifications and provide refresher training as needed. [5]

• Implement a system for coordinating crane operations when multiple cranes are working in the same area.

Establish clear communication protocols and designated signal persons. [2]

• Maintain good housekeeping practices in and around crane operating areas.

Regularly remove debris and ensure clear access routes. [1] [5]

• Provide and ensure the use of appropriate personal protective equipment (PPE), including hard hats, safety glasses, and high-visibility clothing.

Conduct a PPE hazard assessment and provide training on proper PPE use. [10]

6. Emergency Preparedness

• In the event of a crane malfunction, operators must follow emergency shutdown procedures and immediately report the issue.
• Emergency response plans must include procedures for power line contact, fires, loss of stability, control malfunction, two-blocking, and overload. [6]
• Ensure that the emergency response plan includes the contents described in section 116 of the Occupational Health and Safety Code. [8]
• The emergency response plan must be readily available.

7. Training Requirements

• Crane Operator Training: Operators must be trained and qualified to operate the specific type of crane they are assigned to. Training shall include capacities of equipment and attachments; purpose, use, and limitation of controls; how to make daily checks; energizing sequences; start-up and shutdown procedures; emergency shutdown procedures; general operating procedures; all basic signaling procedures; knowledge of applicable standards and company rules; and practice in operating the equipment. [5] [5]
• Rigger Training: Riggers must be trained in proper rigging techniques, inspection of rigging equipment, and load weight estimation. [5]
• Signal Person Training: All personnel involved in crane operations must be trained on hand signals and communication protocols. [10]
• Competent Operator Training: Training must cover the duties of employers and operators, protection of workers, approved standards for cranes, operation of cranes, maintenance of cranes and signalling. [3]
• Site Evaluation Training: Training must include site evaluation, including checking the route of travel, clearances and ground conditions, including the presence of structures, power lines or other equipment that could constitute a hazard. [3]

8. Monitoring and Review

Review Frequency: Annually, or after any incident or near-miss

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Daily and monthly	Crane Operator and Maintenance Personnel	Regularly inspect cranes for defects and wear.
Incident Review	As needed	Safety Manager	Review incident reports and near-miss incidents involving cranes.
Performance Monitoring	Monthly	Safety Supervisor	Observe crane operations to ensure compliance with safety procedures.
Audit	Annually	Safety Manager and External Auditor	Conduct periodic audits of crane safety program.

9. Special Circumstances

• Crane operations near power lines require strict adherence to safe distances and the use of spotters.
• Night work requires adequate lighting and increased vigilance.
• Adverse weather conditions (high winds, ice, snow) may require suspension of crane operations.
• Ensure that a wind-indicating device is provided on an outdoor storage gantry type crane and on an outdoor overhead crane. [5]

Approval and Sign-off

This risk assessment has been reviewed and approved by:

Assessor: _________________________ Date: __________

Manager/Supervisor: _________________________ Date: __________

Safety Representative: _________________________ Date: __________

This risk assessment must be reviewed annually, or after any incident or near-miss or when significant changes occur.

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