Language
Crane and Electric Hoist Safety: Essential Tips! 90% of lifting accidents can be prevented with proper precautions.
Author:
Release time:
26-09-08
In industrial plant operations, bridge cranes, gantry cranes, and electric hoists are the core lifting equipment used most frequently, widely employed in material handling, equipment installation, workpiece relocation, and other tasks. While they significantly enhance production efficiency, they also constitute high-risk specialized machinery within the facility.
Crane‑related accidents are typically sudden, highly destructive, and pose a high risk of injury or fatality. In most cases, these incidents are not caused by equipment failure but rather by improper operating procedures, inadequate inspections, insufficient maintenance, and weak safety awareness. This comprehensive guide outlines the safe operating procedures for factory cranes and electric hoists, key points for hazard identification, maintenance standards, and absolute do‑nots—making it easy to learn, implement, and self‑inspect. It is ideal for plant‑wide training, team‑level briefings, and safety‑communication campaigns.
I. Recognizing Risks: The Root Causes of Common Accidents Involving Lifting Equipment
A post-incident review of lifting and hoisting accidents at the plant site reveals that the vast majority of incidents are attributable to four primary causes—key pain points in routine safety management:
Improper operation : Overloading during lifting, slantwise pulling or lifting, personnel standing beneath suspended loads, abrupt lifting and lowering, operation with equipment malfunctions
Check for absences : No pre-job inspection was conducted, and potential hazards in the limit switches, brakes, hook, and wire ropes were not identified in a timely manner.
Maintenance deficiency : Lack of regular maintenance, overuse of wear parts beyond their service life, and failure of safety protection devices
Management vulnerability : Operating without a permit, multiple people issuing unauthorized instructions, performing work without supervision, and continuing operations in adverse weather conditions.
Whether it’s a heavy-duty overhead crane for large industrial facilities or a lightweight, versatile electric hoist, all lifting‑related accidents can be prevented and brought under control—key to this is the strict adherence to standardized operating procedures.
II. Comprehensive Safety Operating Procedures for Factory Cranes (Universal for Overhead and Gantry Cranes)
1. Before starting work: Conduct a mandatory pre‑inspection to prevent operation while faulty.
A pre‑startup three‑minute inspection is the first line of defense in ensuring safety; none of its components can be omitted.
Inspect the equipment’s annual inspection label to ensure the crane is within its valid inspection period, with all required documentation in order and complete records maintained.
Inspect the electrical system: switches, wiring, insulation, and contactors must be free of damage, aging, or potential leakage hazards. When multiple pieces of equipment share a common circuit, each should be controlled by its own dedicated switch.
Inspect the core safety devices: the load limiter, upper and lower limit switches, brakes, buffers, and rail clamps shall be in good working order and responsive, with the alarm function operating normally.
Inspect the wire rope: ensure there are no broken wires, broken strands, corrosion, or deformation; verify adequate lubrication; and confirm that the rope ends are securely fastened.
Inspect the hook: ensure there are no cracks or deformations, and that the safety latch is intact and closes smoothly.
Clear the work area, remove all suspended loads and clear the travel path, establish a safety cordon, and prohibit personnel from lingering or passing through.
After the pre-inspection is completed, it must… No-load trial lift After completing one round trip, verify that braking is smooth, operation is free of unusual noises, there is no sticking or jerking, and there is no downward slippage before commencing formal operations.
2. During operations: Strictly adhere to red lines and follow standardized procedures.
Overloading is strictly prohibited. : Operate strictly within the rated load capacity; be vigilant when the load reaches 90% of the rated value, and prohibit lifting at or above 100%; never take chances with hoisting operations.
Oblique pulling and oblique lifting are strictly prohibited. : Lifting must be performed vertically; dragging or diagonally pulling loads is prohibited to prevent swinging of the suspended load, deformation of equipment under stress, and wear‑induced breakage of wire ropes.
It is strictly prohibited to lift people, buried objects, or items that are not securely tied. Loose materials must be secured using dedicated lifting devices or baskets.
During lifting, first raise the load 100–200 mm off the ground, then pause to check for balance, the tightness of the rigging, and braking performance. Only proceed with smooth lifting and operation if no abnormalities are detected.
Throughout the entire operation, a dedicated supervisor and a dedicated monitor shall be assigned; command signals must be standardized and clear, and any unauthorized or haphazard instructions or blind operations are strictly prohibited.
Operate smoothly; prohibit abrupt lifting, lowering, or stopping to prevent excessive swinging of the suspended load and potential injuries from falling objects.
If the equipment exhibits abnormal noises, vibrations, slippage, downward movement, or alarm signals, immediately stop the machine and disconnect the power. Resume operation only after the fault has been identified and rectified.
3. After completing the task: Follow standardized closing procedures and implement closed-loop management.
Park the crane at the designated location, raise the hook to a safe height, and return the lifting attachment to its home position.
Return the control handle to the zero position, disconnect the equipment’s main power supply, and turn off the switch.
Clean dust and oil from the equipment surface, and maintain accurate work records and equipment operation logs.
Inspect equipment status, confirm there are no potential hazards, and complete the shift handover record.
III. Special Safety Regulations for Electric Hoists (High-Frequency, Commonly Mistaken Key Points)
Electric hoists are compact and easy to operate, making them the mainstay for lifting small components in workshops; however, due to their highly flexible operation, The accident rate for violations is far higher than that of large cranes. These specific regulations must be kept firmly in mind.
1. Core Operational Prohibitions
It is strictly prohibited for one person to operate two or more electric hoists simultaneously; each operator shall be assigned a single hoist and a dedicated post.
Prohibit rapid lifting and lowering, as well as frequent inching operations, to prevent motor overheating and wire rope fatigue failure.
The operating handle and cable insulation must be in good condition; maintain a 2-meter safety clearance at the standing position, and strictly prohibit any operations involving pulling or tugging on the cable.
The hook must be subjected to vertical load; it is strictly prohibited to lift loads at an angle, to sling loads diagonally, or to drag materials laterally.
When a suspended load is in the air, operators must remain at their posts and are prohibited from walking under, working beneath, or lingering under the load.
2. Emergency Fault Handling
If, during operation, you encounter malfunctions such as uncontrolled downward movement of heavy loads, jamming, or motor failure, do not panic:
Immediately disconnect the power supply; forced operation and repeated jogging are strictly prohibited.
Quickly assess the surrounding environment and lower heavy objects steadily to a safe, unoccupied area.
Report immediately and affix a warning sign reading “Equipment Malfunction—Do Not Use.” The equipment may be reused only after it has been repaired and verified as compliant by qualified personnel.
IV. Regular Maintenance and Inspections: Safeguarding Equipment Safety Standards
In accordance with the requirements of TSG 51-2023, Safety Technical Code for Lifting Machinery, lifting equipment must undergo periodic maintenance and statutory inspections to ensure that no equipment is put into service while defective.
1. Routine Maintenance (Daily/Weekly)
Clean the equipment body, tracks, and wire ropes, and lubricate the transmission components promptly.
Inspect the tightness of bolts and fasteners to eliminate the risk of loosening or detachment.
Verify the sensitivity of limit switches, braking systems, and alarm devices; if any are found to be inoperative, immediately deactivate them and arrange for repair.
2. Periodic Inspection (Legal Standards)
Bridge and gantry cranes: statutory inspection once every two years.
Electric hoists shall undergo inspection concurrently with their associated lifting equipment; operation beyond the inspection deadline or without proper certification is strictly prohibited.
Equipment that has been newly installed, modified, or overhauled may only be put into service after passing inspection and completing the required registration.
3. Standards for Replacing Wear Parts
Wear‑prone components such as wire ropes, hooks, brakes, and bearings must be replaced immediately once they reach the prescribed limits of wear, aging, or deformation. It is strictly prohibited to continue using them beyond their service life; this measure eliminates equipment failure at the source.
V. The Ten Absolute Red Lines for Lifting Operations (Must Be Memorized by All Employees)
To facilitate team recall and daily self-inspections, we have compiled ten prohibitions for lifting operations: any violation of these rules constitutes a breach, and serious violations may result in accidents.
Unqualified personnel are strictly prohibited from operating any lifting equipment or electric hoists.
Overloading, over‑spanning, and operating beyond the designated scope of lifting operations are strictly prohibited.
It is strictly prohibited to lift or hoist at an angle, drag buried materials, or allow materials to become stuck.
It is strictly prohibited for anyone to stand, pass through, linger, or work beneath suspended loads.
It is strictly prohibited to operate equipment with faults or with malfunctioning protective devices.
It is strictly prohibited to carry out lifting operations in adverse weather conditions (strong winds, rain or snow, and poor visibility).
Rapid ascents and descents, abrupt stops and sharp turns, and rough handling are strictly prohibited.
It is strictly prohibited to lift materials that are not securely tied down, have a shifted center of gravity, or are loose and unsecured.
It is strictly prohibited to have multiple people issue uncoordinated instructions or for a single worker to perform high-risk tasks without supervision.
It is strictly prohibited to operate equipment that has exceeded its inspection interval, lacks proper records, or is not maintained.
VI. In Conclusion: There are no small matters when it comes to safety; compliance is the bottom line.
In factory crane‑lifting operations, there is no room for complacency—no “close enough” or “it’s fine once in a while.” Only 100% compliance with standards and 100% rigor will do.
Behind every lifting accident lies a cumulative pattern of disregarding regulations, skipping inspections, and lowering vigilance. Equipment is a tool of production, and safety is the bottom line. Only through standardized operations, regular maintenance, and rigorous oversight can we effectively prevent rigging accidents, safeguard personnel, and ensure stable production at the plant.
Contact Us
Tel: +86-373-889559
E-mail: hnfeima@126.com fmcrane@feimaelectrichoist.com
Address: Changyuan County, Henan Province, Zhuang Industrial Zone
SAF Coolest v1.3.1.1 设置面板 FQVSD-ZANV-QXSVE-DAS
违禁词： First, best, first-class, leading, unique, king, leader, leader, extreme,
无数据提示
Sorry, the current column has no content for the time being.!
You can view other columns or returnHome Page