In factory workshops, warehouses, and material yards, single girder overhead cranes work like tireless "porters," becoming the backbone of material handling thanks to their flexibility and efficiency. But this "strongman" can turn into a safety hazard if misused—minor issues may lead to equipment damage and downtime, while major ones could result in serious accidents. Having worked with cranes for years, I’ve seen too many mishaps caused by overlooked details. Today, I’ll break down safety essentials from a practical perspective to help minimize risks.
As the old saying goes, "Proper preparation prevents poor performance." Pre-start checks aren’t just a formality—they’re your first line of safety defense. Do this thoroughly, and you’ll avoid over 80% of potential problems.
- Take a close look at main girders, end beams, and other structural parts: Are there signs of deformation (like excessive deflection of the main girder), cracked welds (especially at joints), or loose bolts? Never ignore even a tiny crack—report it immediately and stop operation. Structural failures are no small matter.
- The track is like the crane’s "runway": Is the track surface evenly worn? Any dents or bulges? The end stops (the "bumpers" preventing derailment) must be firmly welded. Last year, I saw a factory where a loose end stop caused a crane to derail and nearly crash through the workshop wall.
- Wire ropes and hooks: These are critical for lifting—inspect them as carefully as you’d check your own palm. Replace ropes with broken strands, kinks, bulges, or over 10% wear on diameter. For hooks: If the critical section is worn by over 10% or has cracks (even tiny ones), scrap it immediately. Don’t overlook the hook’s anti-slip latch; it’s a small part that can save lives.
- Brake system: Test brakes rigorously—lift the load 30cm off the ground and hold. If it slips more than 10cm, stop use immediately. A workshop once had a near-disaster because worn brake pads weren’t replaced, causing a load to drop suddenly (luckily, no one was below).
- Electrical wiring: Check for crushed or damaged cables, loose terminals, and reliable grounding (use a megohmmeter—resistance must be ≤4Ω). Pay extra attention during rainy seasons; electric shocks are no joke.
- Keep the work area clear: No clutter on the ground, adequate passage space (at least 1 meter wider than the crane), and sufficient lighting. Add temporary lights if needed—poor visibility leads to mistakes.
- Operators must be "mentally prepared": No uncertified operation—this is a red line. Coordinate signals with the rigger beforehand (hand gestures, whistles—no confusion). Mixing up "hoist" and "lower" signals has caused accidents before.
Stay focused during operation—keep an eye on surroundings, listen for cues, and never zone out.
- Test lifts are "life-savers": Lift the load 10-30cm, pause! Check if ropes are vertical, hooks aligned, and brakes holding. Those few seconds can prevent big risks.
- Never overload! The rated capacity on the nameplate is non-negotiable. "Just a little extra" isn’t worth it. Last year, a 5-ton crane lifting 6 tons had its rope snap, crashing the load through equipment below.
- Load area is a "no-go zone": Even for an empty bucket, clear the area. I’ve seen someone stand under a load to steady it—when the rope swayed, they fractured a bone.
- Avoid sudden starts/stops: Jerky movements make loads swing violently. Slow down near track ends or when approaching other cranes—keep at least 3 meters distance, no racing.
- Obey signals clearly: Stop immediately if the rigger signals to. Never guess unclear signals—stop and confirm. A miscommunication between operator and rigger once damaged goods because "slow lower" was misheard as "stop."
- Strange noises, burning smells, or faulty brakes? Stop immediately—lower the load safely, cut power, and report. "Finishing the job first" has turned small issues into disasters.
- Use the emergency stop without hesitation! If someone enters the danger zone or equipment malfunctions, cut power first, then handle the situation.
Finish strong—proper shutdown ensures the crane is ready next time.
- Park in the "designated spot": Move to the track’s midpoint, raise the hook over 2 meters (to avoid hitting people), turn off power, and neatly coil cables.
- Do a quick "summary": Wipe oil from hooks and ropes, check for new wear. Log operations—load weights, odd sounds—to inform the next shift.
- Regular maintenance is non-negotiable: Lubricate bearings and gears as needed. Replace wear parts like ropes and brake pads on schedule—don’t wait for failures.
- No operation under the influence of alcohol, fatigue, or illness—slower reflexes spell danger.
- Never use the crane to pull nails or buried objects—ropes and girders can’t handle sideways force.
- Never leave the controls during operation—even a minute’s absence can lead to unexpected movement.
- No clutter on the crane—falling tools or screws can injure people below.
Safe crane operation boils down to "carefulness" and "respect for risks." Every part’s condition and every operational detail ties to equipment longevity and human safety. Turn these guidelines into habits, and you’ll keep operations smooth and everyone safe—that’s what productive work should be.
