Every lift starts before the hook leaves the ground. The safest crane operations follow a repeatable, written pre‑lift routine that verifies the people, the equipment, the site and the load. Use this 2025 checklist as a practical, day‑to‑day workflow for bridge and gantry cranes in workshops, warehouses and production lines.
1) Operator & Team Readiness
- Confirm the assigned operator is trained and authorized for this crane, hoist and capacity.
- Review the lift plan, roles and hand signals (or radio protocol) with all spotters and riggers.
- Check PPE: hard hat, safety shoes, gloves, hi‑vis, fall protection where required.
- Verify a clear communication method and establish a single lift director.
2) Work Area Controls
- Inspect the travel path: no people, pallets, hoses, or obstructions under the bridge or along the runway.
- Confirm lighting is adequate and floor conditions are dry and level.
- Barricade or mark exclusion zones. Assign a spotter at pinch points and intersections.
- Test warning devices (horn, beacon) if fitted.
3) Rigging & Load Verification
- Identify the actual load weight and center of gravity; compare with the hoist and rigging WLL.
- Select slings (chain, wire rope, synthetic) and hardware (shackles, hooks) with adequate capacity and angle factors.
- Check tags and markings are legible; reject gear with cuts, kinks, birdcaging, stretched links or missing latches.
- Plan sling angles (≥60° where possible) and use a spreader beam for wide or fragile loads.
4) Hoist & Crane Functional Checks
- Power on and cycle the pendant/radio: verify up/down, trolley and bridge movement respond correctly.
- Test limit switches (upper/lower, trolley and bridge end stops) without forcing them into a hard stop.
- Observe the hook: latch present and closing; no twists; swivel rotates freely; hook throat not spread.
- Listen for abnormal noises from gearbox, end trucks and brakes; check for oil leaks or loose fasteners.
5) Slinging & Attachment
- Position the hook directly above the load’s CG to avoid side pull.
- Protect slings at sharp edges using corner protectors or padding; avoid choke on fragile loads.
- Remove slack gradually. Keep hands clear; never ride the hook or stand on the load.
6) Test Lift (2–5 cm / 1–2 in)
- Raise just off the support to verify balance, rigging seating and brake holding power.
- If the load tilts or slings slip, lower and correct; never attempt to “pull” the load into balance in the air.
- Re‑check travel path and overhead clearance before proceeding.
7) Controlled Travel
- Lift only as high as needed. Keep the load low, steady and under control with smooth starts/stops.
- Use VFD speeds where available to minimize load swing.
- Maintain line‑of‑sight or a dedicated spotter; pause if communications are unclear.
8) Set‑Down & Post‑Lift
- Lower onto prepared dunnage or supports—never fingers or toes.
- Slack slings slowly, remove rigging and inspect for damage after the lift.
- Record any faults; tag‑out the crane if safety systems failed or abnormalities were observed.
Quick Daily Inspection Points
In addition to the pre‑lift steps, perform these daily checks before the first lift of the shift:
- Pendant/radio condition, emergency stop and horn.
- Upper/lower limit switch function.
- Wire rope or chain condition and proper reeving.
- End‑stop bumpers, rail condition and runway clearances.
- Load test certification label and inspection dates are present and current.
Common Errors to Avoid
- Side pulling or dragging a load to “pick” it free—this can overload the structure and topple the load.
- Guessing the weight or using untagged gear.
- Bypassing limit switches or defeating safety latches.
- Standing beneath a suspended load or allowing bystanders inside the exclusion zone.
Summary
Repeatability prevents incidents. Make this checklist part of your standard work: confirm people, site, rigging, crane and communication before every lift, perform a short test lift, and only then travel to the set‑down point. Document issues and stop the job if anything looks wrong—the safest lift is the one you postpone until it’s right.