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Tower cranes

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Published by SALUS

Tower Crane Safety ==================

Date: 2025-10-05

Duration: \[DURATION] minutes

Presenter: \[PRESENTER NAME]

Location: \[LOCATION]

Objective

To review safety regulations and operational procedures for tower cranes, including inspection, maintenance, and emergency protocols.

Introduction

Tower cranes are essential for many construction projects, but they also pose significant safety risks if not properly operated and maintained. This toolbox talk will cover key safety aspects related to tower cranes.

Key Points

Qualified Operators: Tower cranes must be operated only by qualified and certified personnel. Ensure operators are trained and familiar with the crane's operations, limitations, and emergency procedures. [1]
Wind Speed Limitations: Tower cranes shall not be operated when wind speeds exceed the manufacturer's recommendations or 30 mph. Raising to new operating levels should not occur when wind speed exceeds 20 mph. [1]
Regular Inspections: Conduct thorough inspections of tower cranes at intervals not exceeding one month. Inspections must include all critical components such as blocks, shackles, sheaves, wire rope, connectors, hooks, controls, and braking mechanisms. [5]
Pre-Erection Inspection: Before erecting any crane component, a qualified person must inspect it for damage or excessive wear, paying particular attention to components difficult to inspect later. [2]

[2]

Load Testing After Erection: After each erection, conduct a load test using certified weights or scaled weights using a certified scale with a current certificate of calibration. [6]
Counterweight Requirements: Tower cranes must not be operated without the full amount of ballast or counterweight specified by the manufacturer or a qualified engineer. [1]

[3]

Hazard Identification

Crane Overload: Crane collapse, dropped load, serious injury or fatality.

(Risk: High)

Windy Conditions: Loss of control, crane instability, structural failure.

(Risk: High)

Two-Blocking: Damage to the crane, dropped load, potential for injury.

(Risk: Medium)

Improper Maintenance: Mechanical failure, dropped load, injury to personnel.

(Risk: Medium)

Contact with Power Lines: Electrocution, equipment damage, fire.

(Risk: Critical)

Control Measures

Regular Crane Inspections: Conduct monthly inspections by a competent person, documenting all findings and addressing any issues promptly. [5]
Wind Speed Monitoring: Use a wind velocity device to continuously monitor wind speeds and cease operations when limits are exceeded. [7]
Load Limiters and Indicators: Ensure load moment limiting devices and load indicating devices are functioning correctly and are used to prevent overloading. [2]
Two-Blocking Prevention: Use anti-two-blocking devices and train operators to recognize and avoid two-blocking situations. [4]
Qualified Riggers and Signal Persons: Use qualified riggers for load attachment and signal persons for guiding crane operations, especially in blind lifts.
Power Line Safety: Maintain safe distances from power lines and follow lockout/tagout procedures when working near electrical equipment. [8]

Personal Protective Equipment (PPE) Requirements

Hard Hats: Always wear a hard hat to protect against falling objects and head injuries. Ensure the hard hat fits properly and is in good condition.
High-Visibility Clothing: Wear high-visibility clothing to ensure you are seen by crane operators and other workers on site.
Safety Glasses: Use safety glasses to protect your eyes from dust, debris, and other potential hazards.
Gloves: Wear gloves to improve grip and protect your hands from cuts, abrasions, and other injuries.

Real-World Example or Case Study

In 2008, a tower crane collapsed in New York City due to faulty connections, resulting in multiple fatalities and injuries. This tragic event highlighted the importance of proper inspection, maintenance, and adherence to safety regulations.

Group Discussion

Discuss the following questions:

What are the most common hazards you observe when working around tower cranes?
What steps can we take to improve communication between crane operators, riggers, and signal persons?
How can we ensure that all personnel are aware of the crane's load limits and wind speed restrictions?

Emergency Procedures

In case of crane failure, immediately stop operations and evacuate the area.
If a power line contact occurs, stay inside the cab and wait for utility company to de-energize the lines. Warn others to stay away.
Report all incidents and near misses to the supervisor immediately.

Summary

Recap of main points:

Tower crane safety is critical for preventing accidents and injuries.
Regular inspections and maintenance are essential for safe operation.
Qualified operators and riggers are necessary to ensure safe lifting operations.
Adherence to wind speed limitations and load limits is crucial.

Action Items

Specific actions participants should take:

Review the crane's load chart and operational manual.
Participate actively in pre-shift inspections.
Report any safety concerns to the supervisor immediately.

Report all hazards, near-misses, and incidents to your supervisor immediately.

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8 source record(s)

Sources used for this answer

[1] Subpart 23-8 - Mobile Cranes, Tower Cranes and Derricks (CR23)

Page 1

Open source document

Source excerpt

# CODE RULE 23 SUBPART 23-8 MOBILE CRANES, TOWER CRANES AND DERRICKS # Historical Note Subpart added, filed May 30, 1972 eff. June 1, 1972. ## § 23-8.1 General provisions. (a) Stability and strength. Mobile cranes, tower cranes and derricks used in construction, demolition and excavation operations shall be so constructed, placed and operated as to be stable. No component or part of any such crane or derrick shall be stressed beyond its rated capacity as determined by the manufacturer or builder. (b) Inspection. (1) Every mobile crane, tower crane and derrick shall be thoroughly inspected by a competent, designated employee or authorized agent of the owner or lessee of such mobile crane, tower crane or derrick at intervals not exceeding one month. Such inspections shall include but not be limited to all blocks, shackles, sheaves, wire rope, connectors, the various devices on the mast or boom, hooks, controls and braking mechanisms. (2) A written, dated and signed record of each such inspection shall be completed by the competent, designated employee or authorized agent who made the inspection on an inspection form provided by the commissioner. The most recent record of inspection of a mobile crane, tower crane or derrick shall be posted inside the cab of such crane or derrick under a transparent protective covering or shall be filed in an office on the job site available for examination by the commissioner. Attached to such record of inspection shall be a written designation naming the competent employee or authorized agent. Such attached designation shall be signed by the owner or lessee of such mobile crane, tower crane or derrick. (3) Every mobile crane, tower crane and derrick shall be inspected before being erected or operated for the first time on any job. (4) Adjustments and repairs to mobile cranes, tower cranes and derricks shall be made only by competent, designated persons. (5) A preventive maintenance program shall be established for each m…

[2] Safety and Health Regulations for Construction (OSHA 29 CFR 1926) - 1926.1435 - Tower cranes

Page 10

Open source document

Source excerpt

# Occupational Safety and Health Administration (cont.) ## 1926.1435(e)(6)(iv) (cont.) Post-erection inspection. In addition to the requirements in § 1926.1412(c), the following requirements must be met: - 1926.1435(f)(3)(i) A load test using certified weights, or scaled weights using a certified scale with a current certificate of calibration, must be conducted after each erection. - 1926.1435(f) (3) (ii) The load test must be conducted in accordance with the manufacturer's instructions when available. Where these instructions are unavailable, the test must be conducted in accordance with written load test procedures developed by a registered professional engineer familiar with the type of equipment involved. - 1926.1435(f)(4) Monthly. The following additional items must be included: - 1926.1435(f)(4)(i) Tower (mast) bolts and other structural bolts (for loose or dislodged condition) from the base of the tower crane up or, if the crane is tied to or braced by the structure, those above the upper- most brace support. - 1926.1435(f)(4)(ii) The upper-most tie-in, braces, floor supports and floor wedges where the tower crane is supported by the structure, for loose or dislodged components. - 1926.1435(f)(5) Annual. In addition to the items that must be inspected under § 1926.1412(f), all turntable and tower bolts must be inspected for proper condition and torque. [75 FR [redacted postal code], August 9, 2010] Scroll to Top OSHA Standards Enforcement Topics Media Center Contact Us

[3] Safety and Health Regulations for Construction (OSHA 29 CFR 1926) - 1926.1435 - Tower cranes

Page 3

Open source document

Source excerpt

# Occupational Safety and Health Administration (cont.) and top climbing), the employer must: - 1926.1435(b)(7)(i) - Comply with all manufacturer prohibitions. - 1926.1435(b)(7)(ii) Have a registered professional engineer verify that the host structure is strong enough to sustain the forces imposed through the braces, brace anchorages and supporting floors. - 1926.1435(b)(8) - Counterweight/ballast. - 1926.1435(b)(8)(i) Equipment must not be erected, dismantled or operated without the amount and position of counterweight and/or ballast in place as specified by the manufacturer or a registered professional engineer familiar with the equipment. - 1926.1435(b)(8)(ii) The maximum counterweight and/or ballast specified by the manufacturer or registered professional engineer familiar with the equipment must not be exceeded. - 1926.1435(c) Signs. The size and location of signs installed on tower cranes must be in accordance with manufacturer specifications. Where these are unavailable, a registered professional engineer familiar with the type of equipment involved must approve in writing the size and location of any signs. - 1926.1435(d) - Safety devices. - 1926.1435(d)(1) Section 1926.1415 does not apply to tower cranes. - 1926.1435(d)(2) The following safety devices are required on all tower cranes unless otherwise specified: - 1926.1435(d)(2)(i) Boom stops on luffing boom type tower cranes. 1926.1435(d)(2)(ii)

[4] Safety and Health Regulations for Construction (OSHA 29 CFR 1926) - 1926.1435 - Tower cranes

Page 6

Open source document

Source excerpt

# Occupational Safety and Health Administration (cont.) Trolley travel limiting device. The travel of the trolley must be restricted at both ends of the jib by a trolley travel limiting device to prevent the trolley from running into the trolley end stops. Temporary alternative measures: 1926.1435(e)(5)(i)(A) Option A. The trolley rope must be marked (so it can be seen by the operator) at a point that will give the operator sufficient time to stop the trolley prior to the end stops. 1926.1435(e)(5)(i)(B) Option B. A spotter who is in direct communication with the operator must be used when operations are conducted within 10 feet of the outer or inner trolley end stops. 1926.1435(e)(5)(ii) Boom hoist limiting device. The range of the boom must be limited at the minimum and maximum radius. Temporary alternative measures: Clearly mark the cable (so it can be seen by the operator) at a point that will give the operator sufficient time to stop the boom hoist within the minimum and maximum boom radius, or use a spotter who is in direct communication with the operator to inform the operator when this point is reached. ## 1926.1435(e)(5)(iii) Anti two-blocking device. The tower crane must be equipped with a device which automatically prevents damage from contact between the load block, overhaul ball, or similar component, and the boom tip (or fixed upper block or similar component). The device(s) must prevent such damage at all points where two-blocking could occur. Temporary alternative measures: Clearly mark the cable (so it can be seen by the operator) at a point that will give the operator sufficient time to stop the hoist to prevent two-blocking, or use a spotter who is in direct communication with the operator to inform the operator when this point is reached. ## 1926.1435(e)(5)(iv) Hoist drum lower limiting device. Tower cranes manufactured after November 8, 2011 must be equipped with a device that prevents the last 2 wraps of hoist cable from being spoole…

[5] Subpart 23-8 - Mobile Cranes, Tower Cranes and Derricks (CR23)

Page 4

Open source document

Source excerpt

# Historical Note (cont.) ## § 23-8.1 General provisions. (cont.) (b) The safety factor for boom pendants or standing ropes shall be not less than 2.5. (iv) The safety factors specified in subparagraphs (i), (ii) and (iii) above shall be determined on the basis of rope loads resulting from crane or derrick manufacturers' ratings, with approved reeving, published nominal breaking strengths of new ropes and with load and boom stationary. (2) Hoisting rope. When the hook of the hoist of any mobile crane, tower crane or derrick is resting on the ground or equivalent elevation at least two full wraps of the hoisting rope shall remain on the drum of such crane or derrick. (3) Replacement rope. Replacement ropes for any mobile crane, tower crane or derrick shall be at least the equivalent in strength and grade as the original ropes furnished by the manufacturer or builder of such crane or derrick. (4) Eye splices. Eye splices shall be made in an acceptable manner and rope thimbles shall be used in the eye. (5) U-bolt clips. U-bolt clips shall have the U-bolt section on the dead or short end, and the saddle on the live or long end of the rope. Spacing and number of clips shall be in accordance with manufacturer's recommendation. Clips shall be of drop-forged steel. When a newly installed rope has been in operation for at least one hour, all nuts on the clip bolts shall be re-tightened and they shall be re-checked for tightness at monthly intervals thereafter. (6) Special fittings. Swaged, compressed or wedge-socket fittings shall be applied as recommended by the manufacturer of the rope or fittings or by the manufacturer or builder of the mobile crane, tower crane or derrick. (7) Rope inspection. (i) Daily. All running ropes in continuous service on a mobile crane, tower crane or derrick shall be visually inspected at least once every working day. (ii) Monthly. All ropes in use on a mobile crane, tower crane or derrick shall be thoroughly inspected…

[6] Safety and Health Regulations for Construction (OSHA 29 CFR 1926) - 1926.1435 - Tower cranes

Page 9

Open source document

Source excerpt

# Occupational Safety and Health Administration (cont.) ## 1926.1435(e)(6)(iv) (cont.) 1926.1435(e)(6)(vi) Load indicating device. Cranes manufactured after November 8, 2011 must have a device that displays the magnitude of the load on the hook. Displays that are part of load moment limiting devices that display the load on the hook meet this requirement. Temporary alternative measures: The weight of the load must be determined from a source recognized by the industry (such as the load's manufacturer), or by a calculation method recognized by the industry (such as calculating a steel beam from measured dimensions and a known per foot weight), or by other equally reliable means. This information must be provided to the operator prior to the lift. - 1926.1435(f) - Inspections. - 1926.1435(f)(1) Section 1926.1412 (Inspections) applies to tower cranes, except that the term "assembly" is replaced by "erection." Section 1926.1413 (Wire rope--inspection) applies to tower cranes. - 1926.1435(f)(2) Pre-erection inspection. Before each crane component is erected, it must be inspected by a qualified person for damage or excessive wear. - 1926.1435(f)(2)(i) The qualified person must pay particular attention to components that will be difficult to inspect thoroughly during shift inspections. Submit Feedback - 1926.1435(f)(2)(ii) - If the qualified person determines that a component is damaged or worn to the extent that it would create a safety hazard if used on the crane, that component must not be erected on the crane unless it is repaired and, upon reinspection by the qualified person, found to no longer create a safety hazard. - 1926.1435(f)(2)(iii) - If the qualified person determines that, though not presently a safety hazard, the component needs to be monitored, the employer must ensure that the component is checked in the monthly inspections. Any such determination must be documented, and the documentation must be available to any individual who conduct…

[7] Subpart 23-8 - Mobile Cranes, Tower Cranes and Derricks (CR23)

Page 10

Open source document

Source excerpt

# Historical Note (cont.) ## § 23-8.3 Special provisions for tower cranes. (cont.) (d) Inspection and maintenance. (1) Tower cranes shall be inspected and maintained in accordance with the manufacturers' recommendations. (2) Where the mast of any tower crane runs through floor openings in the building or other structure in which the crane is mounted and the mast is secured by wedges or braces, such wedges or braces shall be inspected for tightness and dislocation at least twice each working day. (e) Operation of tower cranes. (1) Operators. Tower cranes shall be operated only by persons who are qualified in accordance with the provisions of section 23-8.5 of this Subpart. (2) Operation in windy conditions. Tower cranes shall not be operated when the wind speed is at any time greater than 30 miles per hour. Tower cranes shall not be raised to new operating levels when the wind speed exceeds 20 miles per hour. (3) Operation without counterweight prohibited. No tower crane shall be operated without the full amount of ballast or counterweight in place as specified by the manufacturer or builder of the crane or by a professional engineer licensed to practice in the State of New York. ## Historical Note Sec. added, filed May 30, 1972 eff. June 1, 1972. ## § 23-8.4 Special provisions for derricks. (a) Bracing of foot blocks. The foot blocks of every derrick shall be securely supported and firmly anchored against movement in any direction. (b) Guys. (1) Number and spacing. The top of any guy derrick mast more than 25 feet in height shall be steadied by not less than six wire rope guys so spaced as to make the angles between adjacent guys approximately equal. (2) Attachment. Wire rope guys shall be secured by either weldless steel sockets, thimble and splice connections, thimbles with proper size and numbers of rope clips or cast steel guy plates having grooved bearing surfaces of the same shape and size as the wire rope thimbles, using a spliced or wire rope…

[8] Subpart 23-8 - Mobile Cranes, Tower Cranes and Derricks (CR23)

Page 9

Open source document

Source excerpt

# Historical Note (cont.) ## § 23-8.3 Special provisions for tower cranes. (cont.) (iii) To limit the load being lifted to no more than 110 percent of the rated load upon completion of the static overload test as specified in paragraph (a) (4) of this section 23-8.3, above. (2) Cabs and remote control stations. (i) Tower crane cabs and remote control stations for such cranes shall be protected from falling objects and material and from the elements. (ii) Cab windows shall be constructed of transparent safety glazing material and shall provide clear visibility in all directions. (iii) Cabs and remote control stations for tower cranes shall be heated to a temperature of at least 60 degrees Fahrenheit during cold weather whenever occupied. (iv) Cabs and remote control stations for tower cranes shall be adequately ventilated. (3) Accessibility. Adequate and safe means of access to and egress from the cabs and machinery platforms of tower cranes shall be provided. Where it is necessary to inspect the jib attachments located on the jib of any tower crane, a footwalk with suitable handrails shall be provided for such inspections. (4) Brakes. In addition to the hoisting brakes required by this Subpart, tower cranes shall be provided with the following: (i) Slewing brake. Every tower crane shall be provided with a brake having adequate holding power in either direction to prevent movement of the jib when desired during normal crane operation. Such brake shall be capable of being set in the holding position and kept there without attention from the operator. (ii) Trolley brake. The trolley of every tower crane shall be provided with an automatic brake or device capable of stopping movement of the trolley in case of trolley rope breakage. (5) Electrical equipment. (i) All electrical equipment of tower cranes shall be grounded. (ii) All tower cranes shall be provided with lightning protection. (iii) All controls of tower cranes shall be of the d…

Publication receipt

Publisher: SALUS
Final reviewer: Francis Langlois
Original answer: Oct 5, 2025

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