In brief
Safety on bridge and overhead cranes has three layers: the operator's start-of-shift check, correct use of the controls and nobody standing beneath a suspended load. Under Annex III of the Regulation on Work Equipment, cranes undergo periodic inspection at least once a year unless the standard sets a shorter interval; a load test at the operating or lifting capacity is carried out at every inspection, and an overload test with a coefficient at most every three years. Only designated and trained persons operate the crane.
Why should overhead crane safety be treated separately?
In metal and machinery businesses, the overhead crane is the backbone of production: it changes dies, carries sheet metal to the machine, lifts casting ladles and loads products for dispatch. Because it is used all day, it looks "routine", and that is exactly why its risks are overlooked. Yet a single suspended load passing over the line can affect several people at once.
Overhead crane safety is governed by the Regulation on Health and Safety Conditions for the Use of Work Equipment. The regulation's basic rules for this equipment are:
- Annex I 3.2.2: The maximum load that can be lifted is marked clearly visible on the machine; lifting accessories are also marked to show their safe use characteristics.
- Annex I 2.4: Where its hazards and stopping time require it, work equipment is fitted with an emergency stop system.
- Art. 8: Work equipment involving specific risks is used only by persons designated to use it; its maintenance and repair are carried out by persons specifically designated for that task.
- Arts. 10 and 11: Written instructions for use are kept with the equipment; the person who will use it is trained before use.
Daily start-of-shift check
Just as the regulation leaves periodic inspection to authorised persons, it also requires the employer to keep the equipment in a safe condition throughout its use. The daily check is the simplest tool for this. A sample list for the check the operator carries out in a few minutes at the start of the shift:
| Checkpoint | What to look for | If non-compliant |
|---|---|---|
| Hook and safety latch | Is the latch in place and closing, is the hook opened out or cracked? | Crane not used, maintenance called |
| Wire rope or chain | Broken wires, crushing, birdcaging, wear, corrosion? | Crane not used |
| Control buttons | Are direction markings legible, do buttons spring back? | Faulty control replaced |
| Emergency stop | Does pressing it stop all movements? | Crane not used |
| Upper limit switch | Does it cut motion when the hook block is raised slowly? | Crane not used |
| Brake | Does it hold under load without slipping? | Crane not used |
| Audible and visual warning | Does it work during movement? | Maintenance called |
| Travel path | Any obstruction on the rail or along the bridge path? | Obstruction removed |
| Slings and accessories | Is the label legible, any cuts, knots or deformation? | Accessory withdrawn from use |
Record the check on a form and hang it at the crane. The rule that the crane is not used without the check is the real value of this form. Compare the items on the list with the manufacturer's user manual; if the manual specifies additional checks, add them to the list.
Using the crane controls
Most mistakes in using crane pendant controls stem from haste and habit. Basic rules for operating a bridge crane:
- Know the capacity. Do not exceed the maximum load on the label. On cranes whose operating capacity has been reduced, the operating capacity is marked visibly under Annex III 2.2.5; loads above it may not be lifted without retesting.
- Lift the load vertically. Do not side-pull or drag the load; the rope may jump off the drum and the load may swing.
- Lift a little first and stop. Raise the load a few centimetres, check the brake and the attachment, then continue.
- See the load path. If the operator cannot see the whole load path, a trained and experienced signaller is assigned under Annex II 3.2.3.
- Avoid sudden movements. Stop the movement before changing direction; use stepped speeds to reduce swing.
- Do not leave a load suspended. Under Annex II 3.2.6, a suspended load is not left unattended unless access to the danger zone is prevented or the load is securely held in suspension.
- Switch off the control when you leave it. With radio remote controls, switch the control off to prevent unauthorised use.
- Plan tandem lifts with two cranes. Under Annex II 3.2.5, if the same load is to be lifted by two cranes, an arrangement is set up to ensure coordination between the operators.
Before maintenance on the electrical panel or on the crane, the energy must be isolated and locked out; we described the steps in our article on the five safety rules in electrical work.
Why is standing under a crane load prohibited?
Annex II 3.1.3 is clear: unless technically unavoidable, measures are taken to ensure that no one is beneath a lifted load; loads are not moved over unprotected workplaces where workers may be present. Where this is not possible, appropriate working methods are defined and applied.
The rule looks simple, but in the field it is broken in the following situations:
- Going under the load to "hold and guide" it. Use a tag line or a guiding pole instead.
- The crane route passing over a walkway or a line of machines. Mark the route on the floor and, if possible, separate the walkway.
- The person who attached the sling waiting nearby as the load is lifted. The slinger must move to a safe distance before the load is lifted.
Choosing slings and lifting accessories
Even if the crane itself is sound, the load falls from the weakest link: the sling, chain, shackle or hook. Under Annex II 3.1.4, lifting accessories are selected according to the load to be lifted, the gripping points, the attachments and the atmospheric conditions, taking into account the shape and construction of the sling. Under Annex II 3.1.5, accessories are stored so that they are not damaged or degraded.
Rules that work in the field:
- Do not use a sling without a label. A sling whose working load limit cannot be read is a sling whose capacity is unknown.
- Take the angle of attachment into account. On multi-leg slings, the load on each leg increases as the angle between the legs widens; read the capacity for the angle in the sling table.
- Protect against sharp edges. Use textile slings with corner protectors on sheet and profile edges.
- Do not tie knots. A knotted chain or sling loses its capacity.
- Store them hanging. Do not leave slings on the floor or in oil and chemicals; use a sling rack.
As lifting accessories, slings are also subject to annual periodic inspection under Annex III. Check that the list of accessories in the inspection report matches the slings in the field; no sling not on the list should be used.
Annual periodic inspection and crane load test
Annex III, Table 2 of the Regulation on Work Equipment covers bridge cranes; unless the relevant standard sets a shorter interval, the maximum inspection interval is 1 year. The inspection is carried out against the criteria in crane standards. Under Annex III 2.2.1, an examination is carried out at every periodic inspection and the crane load test is applied in two stages:
| Test | Frequency | Test load |
|---|---|---|
| Load test at every periodic inspection | At most once a year | Operating capacity if defined, otherwise lifting capacity |
| Overload test with coefficient | At most every three years and after every major maintenance or repair | Lifting capacity × coefficient (as a general rule, 1.25 static, 1.1 dynamic) |
The inspection is carried out by authorised mechanical, mechatronics, metallurgical and materials, or manufacturing engineers registered in EKİPNET (the Ministry's register of authorised inspectors), technical teachers who graduated from the relevant departments, or mechanical technicians or higher technicians. The contract between the employer and the person carrying out the inspection is approved on ISG-KATİP, the Ministry's online OHS registration system, at least one day before the inspection. Repairs to the bridge structure such as welding, cutting or grinding, and replacement of parts other than the rope, chain and similar suspension gear, count as major maintenance and repair (Art. 6/A); after these operations, the inspection and the overload test are repeated. The full interval table is in our article on periodic inspection intervals.
Operator training and certification
Training the crane operator before use is a requirement of Art. 11 of the Regulation. Training should cover the crane's own operating instructions, rigging and sling selection, signalling and what to do in an emergency. Assess whether the job requires a vocational training certificate based on whether the operator's work is among the jobs listed in the annex to the Vocational Training Regulation and on the relevant MYK (Vocational Qualifications Authority) rules; see occupations requiring an MYK certificate.
We plan vocational training through our solution partners working under protocols with Public Education Centres: 40-hour modules approved by MEB (the Ministry of National Education) are selected together with the business according to its line of production. Details are in our vocational training service. For planning the annual inspection and following up reports, see our periodic inspection service, and for sector risks, our metal and machinery sector page.
Frequently Asked Questions
How often is an overhead crane periodically inspected?
Under Annex III, Table 2, the maximum interval for cranes is one year unless the relevant standard sets a shorter one. An inspection is also carried out after major maintenance and repair work.
Is a crane load test carried out every year?
Yes, a load test at the operating or lifting capacity is carried out at every periodic inspection. In addition, at most every three years and after every major maintenance or repair, a test is applied with a load obtained by multiplying the lifting capacity by a coefficient.
Can any employee operate the crane?
No. The crane should be operated only by persons designated to use it who have been trained before use. Set up an arrangement that prevents the control from being used by unauthorised persons.
What should be considered with radio-controlled cranes?
A radio remote control allows the operator to watch the load from a distance and from a better angle, but it increases the risk of connecting to the wrong crane and of unauthorised use. Which crane the control belongs to should be clearly labelled, it should be switched off and kept by an authorised person when not in use, and the emergency stop button should be tested at the start of every shift.
Is quickly passing under the load also prohibited?
Yes. Unless technically unavoidable, measures are taken to ensure that no one is beneath a lifted load, and loads are not moved over unprotected places where workers may be present. A short passage does not change the risk.
Equipment inventory and an inspection calendar under the new Annex III, with inspections carried out through our solution partners, plus report and defect follow-up.
Bursa SİSTEMER OSGB Technical Team — written from the field experience of our OHS specialists and workplace physicians. Legal information is valid as of the publication/update date; contact us for an assessment specific to your business.