Crane operations present significant hazards by nature, making preparation and precaution a must to prevent incidents. A comprehensive pre-lift checklist not only helps avoid crane accidents and injuries but also ensures operational efficiency and regulatory compliance. In essence, clear communication, thorough planning, systematic inspections, and competent personnel are the cornerstones of a safe lifting operation. The following checklist provides a structured overview of the key inspections, assessments, and safety controls required before any crane lift begins.

1. Crane inspection

Verifying the operational readiness of the crane and all associated equipment is the first and most essential step. Mechanical faults or overlooked wear can quickly escalate into catastrophic failures, so each component must be thoroughly checked before anything else.

a. Crane condition checks

Confirm that the crane’s configuration, model, and rated capacity match the lift plan parameters, including radius, boom length, and angle. Examine the boom, jib, and other related components for dents, cracks, or metal fatigue, particularly at connection points. Ensure that boom pins, bushings, and bolts meet the manufacturer’s specifications, and that all are properly secured.

Counterweights should match the planned configuration and be correctly positioned. Within the cab, check that all controls, mirrors, and displays are functional and that the operator’s seat allows for clear visibility and control. Any defects should be reported and corrected immediately before proceeding.

b. Ground stability and condition check

Assessing ground stability is crucial for load-bearing safety. The surface beneath the crane must support both dynamic and static loads without risk of settlement. If there’s insufficient confidence regarding the site’s soil conditions, deploy outrigger floats or crane mats to distribute pressure evenly. These supports should be inspected for integrity, ensuring they have no signs of cracking or excessive wear.

Before setup, liaise with utility services to locate underground utilities such as pipelines, tanks, or drainage systems that may collapse under excessive weight. Use the crane’s internal indicators or external levelling devices to ensure perfect stability. Outriggers must be fully extended and evenly loaded, in strict accordance with manufacturer guidelines.

c. Rigging equipment check

Rigging components must undergo the same level of scrutiny. Inspect slings, hooks, shackles, and blocks for any signs of wear, corrosion, or deformation. Wire rope slings should not have more than six broken wires per lay or three broken wires within a single strand. Synthetic slings must be free from cuts, burns, or chemical degradation.

Examine hooks for cracks or stretching; the latch mechanism must close completely. Shackles and pins must thread easily, with no evidence of galling or thread damage. All rigging components should be appropriately rated for the intended load and compatible with one another.

d. Functional tests

Before handling any load, conduct a no-load operational test. Move the boom, jib, and hoist through their full range of motion to detect irregular noises or jerky movements. Verify that all safety mechanisms, such as the load moment indicator, anti-two-block device, and swing brakes, function correctly.

A light-load test should follow, mirroring the planned lifting sequence. This ensures smooth spooling of the hoist drum, proper control response, and effective communication among the operator and signal personnel. Confirm that emergency stop systems and backup alarms are operational.

Record all findings from the inspection and note any deficiencies and the corresponding corrective actions taken. Any equipment failing inspection should be removed from service until repairs are completed and verified.

2. Site preparation

A safe lifting environment begins with a properly prepared worksite. Site preparation focuses on identifying and mitigating hazards that could interfere with crane operations, personnel safety, or load stability.

a. Obstacle clearance

Survey the entire lift area to ensure safe clearance from nearby structures, power lines, and utilities. Maintain the legally required minimum distance from energised electrical lines; if unavoidable, coordinate with the utility provider to implement isolation or de-energisation procedures.

In addition to overhead hazards, underground utilities such as gas lines, cables, and drainage systems must be located and marked. Establish the full swing radius of the crane and measure clearance along the intended load path to prevent collision risks during operation.

b. Personnel and access control

Managing personnel movement is equally critical. Establish exclusion zones around the crane’s operating area using cones, barriers, or fencing, and post visible warning signage. Only authorised personnel should be permitted within these zones.

Assign duties to qualified and trained individuals; riggers, signal persons, and tag line operators must each understand their roles. Effective communication protocols, including standardised hand signals, should be observed at all times. Designate a primary signal person to maintain visual contact with both the operator and the load.

c. Pre-lift safety meeting

Conduct a detailed safety briefing before commencing any lifting work. Review the lift plan, define roles and responsibilities, and discuss site-specific hazards. Walk through the lift sequence step by step, covering emergency procedures, communication methods, and escape routes.

This meeting ensures all personnel understand their responsibilities and are aligned with the plan. It also provides an opportunity to verify communication systems and contingency measures in the event of equipment malfunction or environmental changes.

For operators, regular professional training, such as attending a lorry crane operator course in Singapore, helps reinforce these protocols and ensure compliance with evolving safety standards and local regulations.

3. Lift planning and load assessment

The lift plan serves as the operational blueprint that combines technical calculations, equipment specifications, and procedural details. A well-defined plan minimises uncertainty and ensures every aspect of the operation aligns with safe working practices.

a. Load weight and centre of gravity

Precise load weight determination is vital. Use manufacturer data, certified scales, or engineering calculations to establish an accurate figure. Never rely on estimation.

Equally, determine the load’s centre of gravity to maintain balance and control. Asymmetrical or irregular loads may require additional engineering assessment or a controlled trial lift to verify stability. During trial lifts, monitor for tilting or shifting and adjust rigging as necessary. The total load must always remain within the crane’s rated capacity.

b. Rigging setup

Select rigging components with adequate working load limits (WLL) exceeding the anticipated load weight. Observe sling angles – wider angles reduce effective capacity and increase tension on rigging elements. Ensure even load distribution across multiple pick points and confirm hardware compatibility throughout the setup.

Rigging should follow the manufacturer’s recommendations precisely. Never substitute components or modify configurations without engineering approval. Proper rigging not only secures the load but also prevents lateral instability during motion.

c. Weather conditions assessment

Environmental factors, particularly wind, can significantly influence lifting safety. Measure on-site wind speeds using calibrated instruments, especially in elevated or partially enclosed environments where gusts can fluctuate.

Loads with large surface areas are more likely to be affected by wind forces. If wind speeds exceed operational limits specified in the lift plan, postpone the lift. Visibility also plays a role; fog, heavy rain, or low light conditions can obscure visual communication, increasing the likelihood of error.

d. Written lift plan and documentation

Every lift, regardless of complexity, must be governed by a lift plan that is penned in ink. This document must include:

• Crane configuration: Boom length, counterweight setup, and operating radius.


• Rigging details: Sling types, capacities, and layout diagrams.


• Environmental conditions: Wind thresholds, temperature limits, and site-specific constraints.


• Personnel roles: Names and responsibilities of operators, riggers, and signal persons.

Once completed, review the lift plan with all participants during a pre-lift meeting. Address uncertainties, document any field adjustments, and ensure all signatures are obtained to confirm understanding. Proper documentation is not merely administrative; it demonstrates due diligence and operational accountability.

Conclusion

Pre-lift safety checks form the foundation of responsible crane operation, which demands precision, teamwork, and vigilance at every stage. A meticulous pre-lift checklist transforms these principles into actionable practices, ensuring that every lift is executed safely, efficiently, and in full compliance with industry standards. By conducting systematic inspections, enforcing site controls, and adhering to a well-structured lift plan, operators and safety managers can significantly reduce the likelihood of accidents and costly downtime.

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