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In brief Yes, wireless overhead crane remote controls are safe, and often safer than wired controls, since the operator stays away from the load during maneuvers. The main risk arises when a spare transmitter is brought into service: two remote controls active on the same crane at the same time can cause an accident. As of 2026, CSA B167 (clause 7.5) requires documented procedures to safely manage spare or backup transmitters. |
An overhead crane that moves by itself! Scary, isn't it?
Poor management of spare remote controls can lead to accidents. An overhead crane could even be activated without the operator's knowledge! Is this possible? Yes, but how often does it happen? More than you think…
But what happened? Did a button get stuck on the control? Does a low battery cause the crane to move involuntarily?
Have you encountered this problem before? If so, you've come to the right place.
As a service technician, I have personally had to go on site for similar emergency calls. And now that I'm a technical representative, I've helped a number of customers to improve their remote control safety management.
In this article, you'll discover the different types of remote controls available on the market, how to avoid using them simultaneously and, above all, what simple procedures to put in place to ensure maximum safety.
But first, are overhead crane remote controls safe?
Are overhead crane remote controls safe to use?
Wireless remote controls, also called radio transmitters, now equip a large share of overhead cranes. Ergonomic and practical, they make operators' jobs easier and offer a safety advantage, since the operator can stay well away from the load during maneuvers.
Of course, these devices aren't immune to faults or breakdowns. To keep operations running when a problem occurs, a second transmitter is usually kept on hand as a spare. This is where a degree of risk comes in, because accidents can happen if two remote controls are used at the same time on the same crane. Note that a requirement now governs this practice: as of 2026, CSA B167 (clause 7.5) requires the owner to put documented procedures in place to safely manage spare or backup transmitters.
That's why it's important to understand the types of remote control available, since they don't all work the same way. While there are many models on the market, let's look at the two main types and how they work.
TRUE STORY RELATED TO SPARE REMOTE CONTROLS
The following real-life incident is a typical example of this hazard: a mechanic was servicing an 18,000-lb. part that had been placed on the ground but was still held by the overhead crane. The worker had placed himself between the load and the wall. Suddenly, the hook went up, lifting the load a few meters high. The worker moved away and alerted a colleague, who immediately closed the disconnect switch. Where did this movement come from? A technician was servicing the spare remote control almost 100m away from the mechanical workshop! Imagine the consequences this event could have lead to!
Ref. : apsm, Accident Alert No. 14 – July 3, 2016
2 types of radio systems, 2 different working methods
The radio system market offers a variety of models to suit different needs. Its selection will depend on several factors, such as budget, required functionalities and even the environment in which it will be used (for example, if it will be used outdoors during the winter).
However, no matter which model you choose, understanding how a radio system works is essential to setting up a safe working method, especially when working with spare transmitters.
Here are the two main models of radio systems on the market, how they work, and the specific working methods for each.
2-transmitter system: risks and solutions
How does it work?
Some systems allow several transmitters to be pre-configured for a single receiver (see the box "Transmitter and receiver"). If one main transmitter fails, the second can be activated immediately. However, these models present a risk: without additional safety measures, the transmitters can take over from each other. What does this mean? As mentioned in the introduction, someone other than the overhead crane's operator can take its control. So how do you ensure safe crane operation with this type of remote control?
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The transmitter and receiver
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A radio system consists of 2 essential components: the transmitter, i.e. the remote control used by the operator to maneuver the overhead crane, and the receiver, i.e. the electronic module connected to the overhead crane which receives the commands.Pros and cons
- No handling required before using the second transmitter. It is pre-configured by the manufacturer to connect to the receiver but is not designed for quick coupling to another receiver.
- Requires a strict safety procedure.
- The price of this solution is generally lower.
Recommended specific working method
With this model of remote control, the first step is to identify all the transmitters, both main and spare. A simple label with the equipment number affixed to the transmitter will avoid errors by linking each transmitter to the overhead crane it controls.
Secondly, spare transmitters must be padlocked to prevent unexpected use by another operator. What does this mean in concrete terms?
It means establishing a clear, written procedure for the use of spare transmitters, involving the use of a locked bag, box or shelf. This prevents inadvertent use of the spare transmitter of this type. All workers concerned should be informed and trained in this method.
Single management system: enhanced safety
How does it work?
These models allow only one transmitter to be active at a time for each receiver. When you insert a new transmitter, it automatically deactivates the previous one. To activate a replacement, the operator must enter a sequence of buttons or perform a configuration from the ground, much like a universal remote control.
Pros and cons
- As replacement transmitters are not assigned to any specific receiver, they can be paired with any receiver. A single replacement transmitter can therefore be available for several pieces of equipment.
- Although the procedure is straightforward, it does require some handling to couple the replacement transmitter with the receiver. This handling is carried out on the ground with the remote controls.
- This system is generally more expensive than the previous one.
Recommended specific working method
Theoretically, there are none, since it's impossible for two transmitters to be used at the same time on the same lifting device. However transmitter identification remains good practice, and training in the use of transmitters is necessary to avoid other types of accidents.
| Activation method | Safe working method | Price | |
|---|---|---|---|
| 2-transmitter system |
Automatic |
Padlocking required and training |
$ |
| Single management system | Manual | Training |
$$ |
Understanding how your remote control works: the key to avoiding accidents
You're now familiar with the 2 main types of remote control and the safety implications of using a spare remote control. The danger is real - an overhead crane can start moving on its own!
It doesn't actually move by itself, as someone has the spare transmitter in hand without your knowledge. Still, that's the impression you get when you witness the scene. And believe me, it can be unsettling! But there are worse things than the fear of an overhead crane moving by itself: an accident occurring because of a lack of understanding of a certain type of radio system.
How can you eliminate the worry and fear of an accident caused by using spare remote controls?
1. Understand how the system works
2. Use a safe work method, such as padlocking if necessary.
3. Train operators according to the system in place.
To find out more about operator training, see the article "Is operator training mandatory? Do you offer this service?". You'll find important information on the types of training offered by companies specializing in the field.
If you would like advice on how to use radio systems safely, please don't hesitate to contact us. We can help you make your operations safer by helping you implement the safest working method for your product. Just click on the "Contact a specialist" button at the bottom of this page.
