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The Occupational Safety Document for Operating an Overhead Crane provides detailed and necessary guidance to ensure a safe working environment when using an overhead crane. This document includes regulations, accident prevention measures, and technical instructions for overhead crane operators, helping to enhance efficiency and ensure safety in an industrial work environment.

Table of Contents

PART I: CURRENT STATUS OF SAFETY WORK RELATED TO OVERHEAD CRANES

I. General Situation

The Ministry of Labour, Invalids and Social Affairs informs sectors and localities of the occupational accident situation in the first 6 months of 2024 and outlines key solutions to proactively prevent incidents and accidents in the last 6 months of 2024. According to reports from 61 out of 63 centrally governed provinces and cities, in the first 6 months of 2024, there were a total of 3,201 occupational accidents nationwide (a decrease of 227 cases, equivalent to 7.09% compared to the same period in 2023), resulting in 3,065 victims (a decrease of 197 people, equivalent to 6.04% compared to the first 6 months of 2023), including both employees under labor contracts and those working without labor contracts. Specifically:

Number of fatal occupational accidents: 320 cases, a decrease of 25 cases (7.25%) compared to the first 6 months of 2023 (including 245 cases in areas with labor relations, a decrease of 28 cases or 10.3%; and 75 cases in areas without labor contracts, an increase of 3 cases or 4.2% compared to the first 6 months of 2023);
Number of deaths due to occupational accidents: 346 people, a decrease of 7 people or 1.98% compared to the same period in 2023 (including 268 in areas with labor relations, a decrease of 13 people or 4.63%; and 78 in areas without labor contracts, an increase of 6 people or 8.33%).
Number of people seriously injured: 810 people, an increase of 26 people or 3.32% compared to the first 6 months of 2023 (including 710 in areas with labor relations, a decrease of 5 people or 0.7%; and 100 in areas without labor contracts, an increase of 31 people or 44.92%).

Download the PDF file Occupational Accident Report – First 6 Months of 2024 issued by the Ministry of Labour, Invalids and Social Affairs.

The occupational accident situation in the first 6 months of 2024 in both sectors with and without labor relations saw a decrease in the number of deaths and fatal accidents compared to the same period in 2023.

II. Some Occupational Accidents While Operating an Overhead Crane

An overhead crane, also known as a bridge crane, is an important tool in many industries, from construction to manufacturing and transportation. However, operating an overhead crane also carries the risk of occupational accidents if not performed safely and correctly. Below are some common accidents when operating an overhead crane:

Falling heavy objects from above: One of the most dangerous accidents is when a heavy object falls from the crane to the ground or onto workers below. The cause may be a technical fault, a failure in the crane’s mechanism, or an error in the operating procedure.
Collision with obstacles: During operation, the crane may collide with obstacles such as columns, walls, or other equipment in the work environment. This can damage the crane’s structure and lead to a risk of accidents.
Derailment or slipping off the track: If the crane is not properly placed on the track or is not maintained correctly, there is a risk that it may derail or slip off the track. This not only causes structural damage but also creates a risk for employees working near the crane.
Electrical shock or explosion: If the crane’s electrical system is not properly maintained, there may be a risk of electrical shock or explosion, especially when the crane is operating near flammable materials or hazardous chemicals.
Risks from unsafe use: Crane operators must comply with safety regulations, including the use of personal protective equipment and adherence to safe operating procedures. Failure to comply can lead to serious accidents.

To minimize the risk of accidents when operating an overhead crane, employee training, regular maintenance, and adherence to safety regulations are very important. Businesses need to ensure that everyone involved in operating the crane is fully trained and understands the necessary safety measures.

PART II: OCCUPATIONAL SAFETY AND HEALTH WHEN OPERATING AN OVERHEAD CRANE

I. Introduction

A. Overview of the importance of occupational safety when operating an overhead crane

Occupational safety when operating an overhead crane plays a crucial role in protecting the health and safety of employees, as well as ensuring work efficiency and cost savings for the business. Adhering to safety regulations and procedures not only helps to minimize the risk of occupational accidents but also creates a positive working environment and motivates employees.

When a business invests in ensuring occupational safety when operating an overhead crane, they are not only ensuring compliance with legal regulations but also demonstrating a spirit of care for the health and safety of their employees. This creates a positive work environment, which helps to boost morale and employee commitment to their work.

In addition, minimizing the risk of accidents also helps businesses avoid negative consequences such as employee injuries, loss of production, and damage to the company’s reputation. Instead, investing in occupational safety when operating an overhead crane brings long-term benefits, enhances work efficiency, and reduces risks in the business operation process.

B. Important safety protocols and regulations when operating an overhead crane

Training and certification: All employees involved in operating an overhead crane must have in-depth training and obtain the relevant certification. This training includes understanding how to operate the crane safely, identifying potential hazards, and knowing the corrective measures to take when necessary.
Regular inspection and maintenance: The overhead crane needs to be inspected and maintained regularly to ensure it operates safely and effectively. Inspection items include the mechanism, electrical system, and control system.
Use of personal protective equipment (PPE): Employees must be fully equipped with and correctly use personal protective equipment such as helmets, safety glasses, gloves, and non-slip shoes.
Adherence to safe operating procedures: Specific safety procedures must be followed every time the overhead crane is operated, including the careful and accurate use of controls and remote control devices.
Hazard classification and assessment: Assessing and classifying the hazards that may occur during crane operation is important to apply effective preventive and protective measures for employees and property.

II. Components and Functions of an Overhead Crane

A. The different components of an overhead crane

Bridge girder: This is the topmost part of the overhead crane, responsible for bearing the load and moving back and forth on the bridge wheels to transport goods or materials.
End trucks: These are the parts with wheels attached to the bridge girder, helping the crane move along the runway or suspension system.
Motor and control system: An electric motor or pneumatic motor is used to generate the necessary power to move the crane. The control system is used to adjust the speed and direction of the crane’s movement.
Cable and wire rope: Cable or wire rope is used to connect the bridge girder to the load block and transmit power from the motor to the bridge girder.
Load block: This is the part of the crane attached to the cable or wire rope and is used to lift and move goods or materials.
Runway: This is the system of rails or suspension beams on which the overhead crane moves, helping to guide and support the crane during its movement.

B. Structure and operating principle of an overhead crane

An overhead crane is a type of lifting machine widely used in many industries to lift and move goods or materials. The structure of an overhead crane usually includes a main bridge girder located high up, connected to end trucks that move along a runway or suspension system.

The operating principle of an overhead crane is based on the use of one or more motors to generate the necessary power to lift and move the load. This motor is usually connected to a power transmission system, typically a cable or wire rope, to transmit power from the motor to the load block.

When the crane is activated, the motor will generate the necessary power to turn the bridge wheels, moving the bridge girder along the runway or suspension system. The load block is attached to the cable or wire rope and is raised or lowered depending on the requirements of the job. The control system is used to adjust the speed and direction of the crane’s movement, ensuring accurate and safe operation.

C. Applications of overhead cranes in the manufacturing industry

Transportation and assembly: Overhead cranes are used to move product components from one location to another during the assembly process. This helps to increase work efficiency and reduce the time required for the production process.
Lifting and shipping: Overhead cranes are used to lift and move goods from the production site to the warehouse or transportation vehicles. This helps to optimize the shipping process and minimize waiting times.
Handling heavy materials: In heavy industries such as the steel industry and automobile manufacturing, overhead cranes are used to handle heavy materials such as steel plates, metal billets, and automotive components efficiently and safely.
Maintenance and repair: Overhead cranes are also used for the maintenance and repair of equipment and machinery during the production process. The use of an overhead crane makes maintenance easier and safer for employees.

D. Risks associated with operating an overhead crane

Risk of falling heavy objects: One of the most serious risks when operating an overhead crane is the risk of heavy objects falling from above onto the ground or onto workers below. This can happen due to a technical fault, a failure of the crane’s mechanism, or negligence during operation.
Collision and impact: During movement, the overhead crane can collide or impact other objects in the work environment, causing damage to the crane’s structure or injury to employees.
Malfunction and electronic disturbance: If the crane’s electrical system is damaged or encounters a problem, a dangerous situation such as an electric shock or explosion can occur, endangering employees and surrounding property.
Employee error: Crane operators who are not sufficiently skilled or do not follow safety procedures correctly can cause unwanted dangerous situations.
Unsafe working environment: An unsafe working environment, including adverse weather conditions or an environment containing toxic chemicals, also increases the risk of accidents when operating an overhead crane.

III. Safety Inspection and Maintenance Before Operating an Overhead Crane

A. Pre-operation safety inspection for an overhead crane

Structural inspection: Inspect the structure of the crane to ensure that there are no cracks, damage, or signs of structural deterioration. This is especially important for load-bearing parts such as the bridge girder and the suspension system.
Electrical and control system inspection: Inspect the electrical and control systems of the crane to ensure that all parts are functioning correctly and without problems. Make sure that all switches, push buttons, and control panels are operating accurately.
Wire rope and brake inspection: Inspect the wire rope and brake system to ensure that they are not broken, cracked, or significantly worn. Make sure that the brake system is working correctly and can stop safely when needed.
Emergency brake inspection: Ensure that the crane’s emergency brake is working correctly and can stop the crane in an emergency.
Personal protective equipment inspection: Ensure that all employees involved in operating the crane are fully equipped with and correctly using personal protective equipment such as helmets, safety glasses, and gloves.

B. Guide to periodic maintenance of an overhead crane

Inspect the crane’s mechanism: Inspect the crane’s mechanism to ensure there are no cracks, damage, or signs of deterioration in the mechanism’s quality. Check parts such as the bridge girder, end trucks, suspension system, and other accessories to ensure they are operating smoothly.
Maintain the electrical system: Inspect and maintain the crane’s electrical system to ensure that all electrical components are working properly and without problems. Ensure that wires, switches, push buttons, and other components are not damaged or showing signs of wear.
Lubricate and clean: Lubricate friction-bearing parts such as the bridge wheels, contact points, and other parts to reduce friction and ensure smooth operation. Cleaning off dust and grease is also an important part of the maintenance process.
Inspect and replace old parts: Inspect parts such as wire ropes, brakes, and other components to ensure they are not damaged or significantly worn. Replace old parts with new ones to ensure performance and safety.
Record and monitor: Record all maintenance activities and perform maintenance measures on a regular basis. Monitor the maintenance schedule and plan for future maintenance work to maintain the safe and effective operation of the crane.

IV. Safe Overhead Crane Operation Procedure

A. Step-by-step guide to a safe overhead crane operation procedure

Pre-operation check: Before starting the crane, thoroughly inspect all components and systems, including the mechanism, electrical system, and controls. Ensure that there is no damage that could affect safety or operational performance.
Training and certification: All employees involved in operating the crane must be fully trained in safety procedures and have the relevant certification. Training includes understanding how to operate the crane safely and recognizing potential hazards.
Use of personal protective equipment (PPE): Everyone involved in operating the crane must be fully equipped with and use personal protective equipment such as a helmet, safety glasses, gloves, and non-slip shoes.
Check the work environment: Before operating the crane, check the work environment to ensure that there are no special hazards or dangerous conditions that could affect safety.
Follow safety procedures: Always follow specific safety procedures when operating the crane, including how to use the controls and remote control devices carefully and accurately.
Communication and warning: Always maintain continuous communication with other members of the work team and warn them of any dangerous situations they may encounter.
Report incidents and keep records: Report any incidents or problems related to crane operation and record all important information about the crane’s operation.

B. Emergency handling measures and incident response mechanisms when operating an overhead crane

Stop the crane immediately: In the event of a detected hazard or incident, employees must stop the crane immediately to prevent the situation from worsening.
Report the incident: As soon as an incident is detected, employees must report the situation to their manager or the safety department to receive assistance and further instructions.
Evacuate the hazardous area: If necessary, employees and anyone else near the hazardous area must be evacuated early to ensure everyone’s safety.
Use the emergency stop buttons: Cranes are often equipped with emergency stop buttons to immediately shut down the machine or stop operation when necessary.
Implement rescue and repair measures: In some cases, it may be necessary to implement rescue and repair measures to resolve the incident and restore the crane’s normal operation.
Training and preparedness: All employees involved in operating the crane must be fully trained in emergency handling measures and response mechanisms, and there must be a plan in place to deal with any unexpected situations.

V. Risk Assessment and Hazard Management in Overhead Crane Operation

A. Identifying potential risks and hazards in overhead crane operation

Risk of falling heavy objects: During the process of lifting and moving goods, there is a risk of heavy objects falling from above, causing injury or property damage.
Collision and impact: The crane moves in a confined space, so there is a risk of collision or impact with other objects, causing damage to both the crane and surrounding items.
Electrical shock and risk of explosion: The crane’s electrical and control systems can malfunction, creating a risk of electric shock or explosion, especially if not maintained regularly.
Employee error: Crane operators who are not sufficiently skilled or who do not follow safety procedures correctly can cause unexpected dangerous situations.
Lack of regular maintenance and inspection: If the crane is not regularly maintained and inspected, components can wear out or break down, increasing the risk of incidents and accidents.

B. Effective hazard prevention strategies when operating an overhead crane

1. Regular inspection and maintenance of the overhead crane for safe operation

Inspect the crane’s mechanism: Ensure that the crane’s structure is not affected by corrosion, cracks, or damage. Check load-bearing parts such as the bridge girder and suspension system to ensure they are operating normally.
Inspect the electrical and control system: Check all electrical and control components of the crane to ensure they are working properly and there are no signs of problems. Ensure that all switches, push buttons, and control panels are operating correctly.
Lubricate and clean: Lubricate friction-bearing parts such as the bridge wheels and contact points to reduce friction and ensure smooth operation. Cleaning off dust and grease is also an important part of the maintenance process.
Inspect and replace damaged parts: Check all parts such as wire ropes, brakes, and other components to ensure they are not damaged or worn. Replace old parts with new ones to ensure performance and safety.

2. Adherence to occupational safety regulations for safe overhead crane operation

Training and instruction: All employees involved in operating the overhead crane must be fully trained in safety measures and operating techniques. Regular training should also be conducted to update knowledge and skills.
Use of personal protective equipment (PPE): Everyone involved in operating the overhead crane must be equipped with and use correctly personal protective equipment such as a helmet, safety glasses, gloves, and non-slip shoes.
Adherence to procedures and regulations: Adhere to all specific safety procedures and regulations set for the operation of the overhead crane. This includes the correct and safe use of remote control equipment.
Communication and collaboration: Communicate effectively with other members of the work team and provide information about any safety hazards or issues they may encounter.
Reporting and risk assessment: Report any incidents or hazardous situations related to the operation of the overhead crane and conduct a risk assessment to implement preventive measures.

3. Identifying and marking safe zones when operating an overhead crane

Identify hazardous zones: First, it is necessary to identify and clearly mark the hazardous zones around the crane, including the crane’s movement area and the crane’s working area.
Identify safe zones: Based on the crane’s range of movement and other safety factors, identify the safe zones around the crane. Ensure that no one is allowed in this zone while the crane is in operation.
Use signs and markings: Use signs, colored tape, and other marking measures to clearly indicate the safe and hazardous zones. Ensure that the signs are placed in easily visible and understandable locations.
Training and communication: Ensure that all employees involved in crane operation are trained on safe and hazardous zones and understand the importance of complying with these safety measures. At the same time, it is necessary to maintain continuous communication with other members of the team to ensure that everyone is aware of and complies with the regulations on safe zones.

4. Use of personal protective equipment when operating an overhead crane

Helmet: A helmet is mandatory when working in an area where there is a risk of falling objects from above or collisions.
Safety glasses: Safety glasses help protect the eyes from falling or flying objects from the work process, especially in dusty working conditions or where there is a risk of collision.
Protective gloves: Using protective gloves can help protect the hands from hard objects, sharp edges, or high temperatures when in contact with parts of the crane.
Safety shoes: Safety shoes with non-slip and puncture-resistant soles can help reduce the risk of injury from impact or collision.
Protective jacket: A protective jacket can help protect the body from falling or impacting objects during work.

5. Emergency procedure and response in case of an incident when operating an overhead crane

Stop the crane immediately: In the event of an incident, the employee must stop the crane’s operation immediately to prevent the situation from worsening.
Report the incident: Report the situation to a manager or the safety department to receive assistance and further instructions.
Evacuate the hazardous area: If necessary, move employees and anyone else near the hazardous area to ensure everyone’s safety.
Use the emergency stop buttons: Cranes are often equipped with emergency stop buttons to shut down the machine or stop operation immediately when needed.
Implement rescue and repair measures: Implement rescue and repair measures to resolve the incident and restore the crane’s normal operation.
Training and preparedness: Ensure that all employees involved in operating the crane are fully trained in emergency procedures and response mechanisms, and have a plan in place to deal with any unexpected situations.

6. Participate in occupational safety courses when operating an overhead crane

Occupational safety and health training is not only a legal requirement but also a commitment to the safety and health of workers. It helps employees recognize and deal with hazards and dangerous situations, thereby minimizing accidents, injuries, or fatalities in their daily work.

The risk of accidents is always present and can happen at any time in the work environment due to the possibility of human error and the unpredictability of all situations. This emphasizes the need for occupational safety training and constant vigilance.

When participating in occupational safety training at An Toan Nam Viet Center, workers will be methodically trained from theory to real-life risk scenarios. Accordingly, there will be measures to identify and prevent occupational accident risks that may occur during work. After the training course, trainees will take occupational safety tests in order to obtain a occupational safety certificate. From there, workers will have a clear understanding of safety knowledge as well as a valid certification for work.

VI. Factors Affecting Occupational Safety When Operating an Overhead Crane

A. How do weather conditions affect the operation of an overhead crane?

Weather conditions can significantly affect the operation of an overhead crane. In severe weather conditions such as rain, snow, strong winds, or high temperatures, operating an overhead crane can become dangerous or difficult. Some specific effects may include:

Rain and snow: Rain and snow can increase the risk of slipping and making the working surface of the crane slippery, posing a danger to employees and property. In addition, snow accumulating on the crane and its structural parts can cause an increase in weight and reduce the crane’s mobility.
Strong winds: Strong winds can cause the crane to become unbalanced or cause lifted materials to lose control. This can lead to serious accidents or property damage.
High temperatures: In high-temperature conditions, parts of the crane can melt or expand, reducing their strength and performance. In addition, high temperatures can also increase the risk of fire or explosion from electrical equipment and machinery.

To cope with severe weather conditions, it is necessary to have a suitable safety plan and measures. This may include suspending crane operations in bad weather, using appropriate PPE, and ensuring that all employees are trained to handle weather-related emergencies.

B. How does the working environment affect the operation of an overhead crane?

Humidity and pollution: A working environment with high humidity or containing dust and chemical particles can reduce the performance of the crane and damage its structural and electrical components.
Temperature and tropical conditions: The ambient temperature of the working environment can also affect the operation of the crane. In tropical or cold environments, the crane’s components can expand or contract, affecting its mobility and overall performance.
Confined workspace: A confined workspace can reduce the crane’s mobility and create a risk of collision with other objects, causing damage to both the crane and surrounding items.
Toxic and explosive gases: In a working environment containing toxic or explosive gases, operating the crane can pose a risk of electric shock or explosion.

C. How does the technical condition of the overhead crane affect its operation?

Operating performance: The overhead crane must be regularly maintained and inspected to ensure smooth and efficient operation. If any problems or failures occur, it can affect the crane’s operational capability and safety.
Safety: The technical condition of the crane is directly related to the safety of the operating process. If there are any problems with the mechanism or control system, it can create a risk of accidents and property damage.
Reliability: The overhead crane must have high reliability to ensure that it can operate stably under all conditions and loads. A technical failure can lead to production interruptions and cause losses in time and money.

D. How do the safety knowledge and skills of the worker affect the operation of the overhead crane?

Understanding of the crane: Employees must understand the structure and operating principle of the crane, including its mechanical parts and control system. This helps them to understand how to operate and maintain the crane safely and effectively.
Knowledge of occupational safety: Employees must be trained in occupational safety rules and accident prevention measures when operating the crane. This includes identifying and assessing potential risks and response measures in case of an incident.
Skills in performing safe operations: Employees must have the skills to perform crane operations safely and accurately. This includes the proper use of the crane’s control devices and safety systems.
Teamwork ability: In a production environment, teamwork is very important. Employees must be able to work together and communicate effectively to ensure safety and efficiency in the crane operation process.

VII. Occupational Safety Training on Safe Overhead Crane Operation Skills

A. Why do overhead crane operators need to be trained in occupational safety?

Reduce the risk of accidents: Occupational safety training helps crane operators to identify and assess potential risks during operation. They are instructed on how to recognize and react correctly when an unexpected situation occurs, helping to minimize the risk of accidents and property damage.
Improve work performance: Employees trained in occupational safety often have a deep understanding of safety rules and procedures. This not only creates a safer working environment but also helps to improve work performance and minimize downtime due to accidents or incidents.
Comply with the law: Occupational safety training helps to ensure that employees comply with legal regulations and provisions related to the operation of overhead cranes. This is important to avoid fines and legal risks for the business.
Build trust and confidence: Occupational safety training helps crane operators feel more confident in their work. They know that they have been equipped with the necessary knowledge and skills to work safely and effectively.

B. Where to get occupational safety training for overhead crane operation?

An Toan Nam Viet is a reputable and high-quality occupational safety training center in Vietnam today. With occupational safety training sessions held continuously at production workshops, factories, or construction sites throughout the country (63 provinces in Vietnam).

To ensure the effectiveness of the training, An Toan Nam Viet prepares carefully and meticulously, down to the smallest detail. From preparing tools, equipment, and teaching aids to curriculum, materials, sound, and lighting.

The occupational safety training instructors at An Toan Nam Viet are experts with many years of experience in the field. They even have research projects identifying hazards in all occupations and how to prevent them.

The instructors’ lectures are drawn from practice and conveyed in the most vivid and easy-to-understand way to the workers. These factors help workers feel comfortable during the learning period and absorb the taught knowledge well. Of course, the knowledge conveyed always adheres to Decree 44/2016/ND-CP. From there, they will grasp many measures to prevent hazards and how to protect themselves. At the same time, they will also apply it most appropriately in their actual work.

VIII. The Significance of Occupational Safety in Overhead Crane Operation

A. The importance of maintaining occupational safety in overhead crane operation

Protecting employees: Occupational safety is the top priority to protect employees from the risk of accidents and injuries during work. Maintaining occupational safety in overhead crane operation helps to minimize the risk of accidents and ensure the health and safety of employees.
Minimizing property damage: Accidents during crane operation not only cause health losses but can also cause significant property damage. Maintaining occupational safety helps to minimize the risk of unwanted incidents and keep equipment and goods protected and safe.
Enhancing work performance: A safe and secure working environment helps to create favorable conditions for employees to work more effectively. When employees feel safe and confident in their work, they are able to concentrate better and improve their work performance.
Complying with the law: Maintaining occupational safety is not only a moral responsibility but also a legal obligation. Complying with occupational safety regulations and rules not only helps to avoid legal penalties but also creates a solid foundation for the business’s operations.

B. Important safety measures to know before operating an overhead crane

Inspect the equipment: Before use, it is necessary to inspect the crane to ensure that all parts are working correctly and there are no signs of damage.
Inspect the work environment: Identify and eliminate any hazards in the work environment, including confined workspaces, obsolete materials, and bad weather conditions.
Classify and control the load: Accurately determine the load of the crane and ensure that it does not exceed the specified load capacity. Use overload protection devices if necessary.
Adhere to safety rules: Ensure compliance with all safety rules for crane operation, including the use of personal protective equipment and adherence to regulations on safe distances.
Contact and communication: Ensure that there is an effective communication system between the crane operator and others in the work area, including the use of signals and communication systems.
Occupational safety training: Complete an occupational safety training course to be issued an occupational safety card by the occupational safety training center to strengthen your profile in accordance with regulations when working.