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 conducted on site, including but not limited to mobile cranes, overhead cranes, and tower cranes. It includes all lifting activities, rigging, signaling, and maintenance related to crane operations. The scope excludes elevators and other permanently installed lifting devices not typically classified as cranes.

2. Risk Assessment Methodology

This risk assessment employs a 5x5 risk matrix to determine risk ratings. The methodology includes hazard identification, risk evaluation (assessing likelihood and severity), implementation of control measures based on the hierarchy of controls (Elimination, Substitution, Engineering, Administrative, PPE), and reassessment of risk after controls are implemented.

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	Medium	High
Major	Low	Medium	Medium	High	Extreme
Moderate	Medium	Medium	High	Extreme	Extreme
Minor	Medium	High	Extreme	Extreme	Extreme
Negligible	High	High	Extreme	Extreme	Extreme

4. Hazard Identification and Risk Evaluation

1. Overloading the crane beyond its rated capacity.

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

Affected Persons: Workers, public, and site visitors

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Ensure that the weight of each load to be hoisted by a crane or hoist is determined and communicated to the equipment operator and to any person rigging the load.
• If the weight of a load to be lifted cannot be accurately determined, the crane or hoist to be used for the lift must have a load weight indicator or an overload prevention system.
• The rated capacity of a crane or hoist must not be exceeded.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

2. Struck-by hazards from the rotating superstructure of the crane.

Potential Consequences: Serious injury or fatality to workers in the swing radius.

Affected Persons: Crane operator, riggers, and workers in the vicinity

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Provide training to each employee assigned to work on or near the equipment in how 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.
• 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

3. Crushing or pinning workers due to insufficient clearance between the crane and nearby objects.

Potential Consequences: Serious injury or fatality.

Affected Persons: Crane operator, riggers, and nearby workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

Control Measures

• Ensure equipment is positioned so that no moving part of the equipment will come within 60 cm (2 ft) of any obstruction in any area accessible to workers.
• If the clearance required by subsection (1) cannot be provided, entry to such areas must be prevented by barriers or other effective means.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Minor	Low

4. Loss of control of the crane due to distractions or impairment.

Potential Consequences: Uncontrolled load movement, collision, or dropped load.

Affected Persons: Crane operator and workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• The operator of a crane or hoist must have full control of the equipment controls whenever the hoisting equipment is in use, and engage in no other duties while operating the equipment.
• The operator of a crane or hoist must not move a load unless the operator is satisfied that the load can be handled safely.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

5. Contact with power lines during crane operation.

Potential Consequences: Electrocution, fire, and equipment damage.

Affected Persons: Workers and public

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Catastrophic	High

Control Measures

• Equipment must be positioned so that no moving part of the equipment will come within 60 cm (2 ft) of any obstruction in any area accessible to workers.
• If the clearance required by subsection (1) cannot be provided, entry to such areas must be prevented by barriers or other effective means.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Major	Medium

6. Improper planning and execution of tandem lifts.

Potential Consequences: Uneven load distribution, equipment failure, dropped load, and potential injuries.

Affected Persons: Workers involved in tandem lifts

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• If a tandem lift is a critical lift or if the lifted load is to be moved laterally, the tandem lift must be carried out under the direction of a qualified supervisor who is not operating a crane, hoist or other piece of powered lifting equipment, and is responsible for the safe conduct of the operation.
• A written lift plan must be prepared for every tandem lift and must be available at the worksite during the lift.
• The lift plan required in subsection (2) must include the following: rigging details; wind speed limitations; maximum hoist line speed; maximum crane travel speed, if applicable; load distribution; the need for and position of signallers.
• If a tandem lift involves the use of a tower crane, the lift plan required in subsection (2) must be certified by a professional engineer.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

7. Failure of crane warning systems.

Potential Consequences: Collisions with other equipment or personnel.

Affected Persons: Crane operators and maintenance personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• A crane, shall be equipped with a warning device, such as a flashing light, horn, bell, or siren. An operator shall use a warning device before starting and intermittently while traveling in an occupied area.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

8. Dropped loads due to rigging failure or improper load securement.

Potential Consequences: Serious injury or fatality.

Affected Persons: Crane operators, riggers, and workers below

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	High

Control Measures

• The operator must not be permitted to leave the control position while the load is suspended.
• No person should be permitted to stand or pass under a load on the hook.
• If the load must remain suspended for any considerable length of time, the operator must hold the drum from rotating in the lowering direction by activating the positive controllable means of the operator's station.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

5. General Control Measures

• Conduct regular inspections of all cranes and lifting equipment to ensure they are in safe working condition.
• Implement a comprehensive preventative maintenance program for all cranes.
• Ensure all crane operators and riggers are properly trained and certified.
• Establish clear communication protocols between crane operators, riggers, and signalers.
• Maintain a safe distance from power lines and other overhead obstructions.

6. Emergency Preparedness

• Ensure emergency stop mechanisms are tested and functional on all cranes.
• Establish and communicate emergency procedures, including evacuation plans and contact information for emergency services.
• Provide training on emergency response procedures, including first aid and fire suppression.

7. Training Requirements

• Crane Operator Certification: Crane operators must be trained and certified in accordance with regulatory requirements and industry standards. Training must include equipment operation, load handling, and emergency procedures.
• Rigger Training: Riggers must be trained and qualified in proper rigging techniques, load securement, and inspection of rigging equipment.
• Signaler Training: All personnel involved in crane operations must be trained on signaling procedures and communication protocols.
• Crane Operation Training: Training shall include all of the following: Capacities of equipment and attachments; Purpose, use, and limitation of controls; How to make daily checks; The energizing sequences, including pneumatic, hydraulic, and electrical sequences; Start-up and shutdown procedures; Emergency shutdown procedures; General operating procedures; All basic signaling procedures, including hand, radio, or telephone signals, where required; Knowledge of this standard and other applicable MIOSHA standards, and company rules and regulations; Practice in operating the assigned equipment through the mechanical functions necessary to perform the required task; Maximum rated capacity of the crane.
• Crane Inspection Training: Maintenance personnel, crane inspectors, and all other users of the crane shall be trained.

8. Monitoring and Review

Review Frequency: Annually, or after any incident or significant change in crane operations

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Daily and monthly	Qualified Inspector	Regularly inspect crane components such as wire ropes, hooks, brakes, and controls.
Performance Indicator	Monthly	Safety Manager	Monitor operator performance and adherence to safety procedures.
Audit	Annually	External Auditor	Conduct periodic audits of crane operations to ensure compliance with safety standards.

9. Special Circumstances

• Crane operations during adverse weather conditions (high winds, heavy rain, snow).
• Nighttime crane operations with reduced visibility.
• Crane operations in congested areas with limited space.

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 significant change in crane operations or when significant changes occur.

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