A Must-Read for Factory Lifting Operations! A Comprehensive Guide to the Safe Operation of Cranes and Electric Hoists—Helping You Avoid 90% of Lifting Accidents.

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Release time:

26-08-26

In factory workshop production, bridge cranes, overhead cranes, and electric hoists are core equipment used with high frequency; material handling, equipment lifting, and workpiece transport all rely on them.

However, this type of lifting equipment is classified as a high-risk special-purpose device. If operated improperly, inadequately inspected, or used in violation of safety regulations, it can easily lead to serious accidents such as falling loads, equipment collisions, personnel entrapment, and electric‑shock injuries. Such incidents may result in equipment damage and production shutdowns at the least, and in loss of life, severe injuries, and substantial economic losses at worst.

Most crane accidents are not caused by equipment failure, but rather by operators’ complacency, neglect of details, and violations of operating procedures. Today, we’ve compiled a comprehensive set of safety operating guidelines for cranes and electric hoists, covering five key areas—pre‑operation, during operation, post‑operation, prohibited red‑line practices, and routine maintenance—to thoroughly address the essential safety considerations for workshop lifting operations. All workshop operators, team leaders, and safety officers must carefully read and strictly adhere to these guidelines.

01 Pre-Work Inspection: Establishing the First Line of Defense for Safety

Crane operations strictly prohibit starting equipment while it is malfunctioning or performing work without proper guidance. Before each shift, a comprehensive inspection must be completed; work may commence only after confirming that the equipment is in proper working condition, thereby eliminating all potential hazards at their source.

1. Equipment Appearance and Structural Inspection

Carefully inspect the crane and electric hoist body for deformation, cracks, or weld failures; ensure the hook is free of wear, cracks, and deformation, and that the anti‑disengagement snap ring and safety device are complete, intact, and function smoothly and effectively. Verify that the wire rope and chain show no broken strands, rust, severe wear, or knots and deformations, and that the rope clips are securely fastened with appropriate tension, in compliance with safety standards.

2. Electrical and Braking System Inspection

Inspect power and control cables for damage, aging, or exposed conductors; ensure that grounding and neutral‑connection protection is secure and reliable to eliminate the risk of electrical leakage. Verify that operator buttons and remote controls are responsive and functional, with no sticking or malfunctions. Confirm that safety devices such as brakes, limit switches, and buffers are in good working order and highly sensitive, that the emergency stop function operates properly, and that the overload protection device can be triggered as intended. Before operating in wet or humid environments, perform additional insulation‑resistance tests to ensure electrical safety.

3. No-Load Trial Hoisting Test (Core and Critical)

Prior to commencing work, a no‑load trial run must be conducted, with repeated testing of lifting, traversing, and start/stop operations to confirm that the equipment exhibits no abnormal noises, vibrations, jerks, or deviations. Before the formal lift, the load shall be raised 100–200 mm off the ground and held for 3–5 seconds to verify braking performance, equipment stability, and the secureness of the rigging. Only after confirming there is no slippage, swaying, or misalignment may normal hoisting proceed.

4. Work Environment and Personnel Verification

Clear the lifting operation area to ensure unobstructed access, and verify that there are no personnel, debris, or equipment obstructing the load’s travel path. In outdoor or open‑air workshops, lifting operations are strictly prohibited during winds of Force 6 or higher, heavy rain, dense fog, or conditions of poor visibility. All operators must be certified and wear appropriate personal protective equipment, including hard hats and non‑slip footwear, and must not work while fatigued or under the influence of alcohol.

02 Operations during work: Strictly adhere to standards and eliminate violations.

Throughout the entire lifting operation, adhere to the principles of steady lifting, steady travel, and steady lowering at low speed and with smooth motion; prohibit abrupt stops, sharp turns, and rapid lifting or lowering; and ensure that all operations are standardized and compliant with established procedures.

1. Strictly adhere to the load limit; overloading is strictly prohibited.

Operate strictly in accordance with the equipment’s rated load; overloading during lifting and operation is strictly prohibited, and it is forbidden to use lifting equipment to drag or pull heavy objects. Oblique pulling and inclined lifting are strictly prohibited, as is lifting loads that are buried underground, compacted, or firmly adhered to surfaces, to prevent uneven stress that could cause wire ropes to break, equipment to topple, or loads to fall.

2. Strictly control work areas to prevent personnel from remaining in hazardous locations.

Under suspended loads and within the operating radius of lifting equipment, no personnel shall stand, pass through, remain, or perform work. Throughout the operation, ensure that “no one remains beneath the load, and the load never passes over anyone’s head.” When hoisting heavy loads, it is strictly prohibited to pass over the heads of workers, production equipment, or material racks; adhere to the “three no‑overpasses” principle. Establish perimeter cordons in the work area, assign dedicated supervisors, and prohibit unauthorized personnel from entering.

3. Standardize operating procedures and eliminate hazardous practices.

Equipment must be started, stopped, and reversed slowly and smoothly; sudden acceleration, emergency braking, and rapid direction changes are prohibited to prevent heavy loads from swinging violently or becoming detached. During lifting operations, if personnel or equipment approach, the bell must be sounded and warning signals issued in advance, and the load should be moved aside at low speed. When a heavy load is suspended, operators must remain at their posts, and it is forbidden to leave the load hanging in the air for extended periods. When securing angular or sharp‑edged workpieces, protective pads or rubber sleeves must be used to prevent wire ropes from being worn through or broken.

4. Unified command, dedicated operator

Lifting operations must be conducted under the exclusive supervision of a designated operator and a designated signaler. Command gestures and verbal signals shall be standardized, clear, and unambiguous, with no multiple or haphazard instructions permitted. Operators must maintain full concentration throughout the entire operation; the use of mobile phones, casual conversation, and unauthorized departure from the post are strictly prohibited. Any abnormalities must be immediately addressed by stopping the equipment.

03 Post-Work Cleanup: Standardized Reset, Long-Term Protection

Many safety hazards stem from improper post‑operation cleanup; performing thorough wrap‑up procedures can effectively prevent equipment damage and secondary accidents.

1. After completing the task, lower the load to the ground smoothly, remove the lifting attachments and ropes, and clean up the area thoroughly.

2. Park the crane and electric hoist at the designated safe location, raise the hook to a safe height, and ensure no load is suspended.

3. Turn off the equipment’s power and the main switch, disconnect the power supply, clean the equipment thoroughly, and remove dust, oil stains, and debris from the unit.

4. Inspect equipment for wear, looseness, or abnormalities; record operational conditions; promptly report and arrange for repairs upon identifying any potential hazards; and strictly prohibit storing equipment with known defects or operating it while faulty.

04 Absolutely Prohibited! The Ten Safety Red Lines for Lifting Operations

The following behaviors are considered to be Serious violation of operating procedures , once discovered, will be subject to strict accountability; all personnel must resolutely prevent this from happening:

1. Operating without a license; unauthorized operation of lifting equipment by non‑qualified personnel;

2. Overloading during lifting, slantwise pulling or lifting at an angle, and lifting heavy objects that are buried, pressed down, or secured;

3. Standing or walking beneath suspended loads, or allowing suspended loads to pass over personnel or equipment;

4. Using cranes or electric hoists to carry or transport personnel as lifting equipment;

5. Operating the equipment with safety devices inoperative or equipment malfunctions unresolved;

6. Operations conducted in adverse weather conditions, such as strong winds, heavy rain, dense fog, or poor visibility;

7. Leaving one’s post without authorization during operations, or departing the worksite while heavy loads are suspended;

8. Improperly secured loads, unstable center of gravity, and unprotected sharp edges—lifting performed without due caution;

9. Uncoordinated command by multiple parties, unauthorized command, and hazardous operations;

10. Equipment is operated in a faulty condition due to prolonged lack of maintenance and annual inspections.

05 Routine Maintenance and Annual Inspections: Extend Equipment Lifespan, Safeguard Safety Standards

Lifting equipment is classified as special equipment. Regular maintenance and timely annual inspections It is a legal requirement and also key to accident prevention.

1. Routine Maintenance: Clean the equipment daily, inspect the wire ropes, hooks, brakes, and limit devices, promptly tighten any loose components, replenish lubricants, and identify potential risks of electrical leakage or jamming.

2. Regular Maintenance: Conduct specialized inspections monthly and quarterly, with a focus on assessing braking performance, safety limit switches, the electrical system, and wear on the metal structure; promptly replace any aged or damaged components.

3. Compliance Annual Inspections: In strict accordance with regulations governing special equipment, conduct official annual inspections on a regular basis and maintain complete records of inspections and maintenance. Equipment that has not undergone annual inspection or has failed such inspection shall be immediately taken out of service.

4. Ledger Management: Establish ledgers for equipment usage, maintenance, and inspections to ensure traceability and end-to-end control.

Lifting operations are high-risk, with hazards that are often difficult to detect. Once A lucky break in violating safety regulations could easily turn into an irreversible accident. All workshop operators and managers must keep this in mind: equipment may tolerate mistakes, but safety brooks no compromise.

By strictly adhering to operating procedures, conducting thorough pre‑shift inspections, maintaining proper practices during operations, and completing post‑operation cleanup, while routinely carrying out equipment maintenance and upholding every safety threshold, we can effectively prevent lifting‑related accidents and ensure both personnel safety and stable production.

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Safety Operating Guide for Factory Electric Hoists: Upholding the First Line of Defense in Lifting Operations