By Marc-André Martineau
Manager & Partner at Industrial Premium Group
In briefNo, you cannot lift a worker with an overhead crane: neither the RSST nor hoist manufacturers permit it. However, the crane structure can serve as an anchor point for a lifeline, but only under strict conditions (engineer approval, zero-energy lockout, risk assessment and training). Alternatives are possible, such as anchoring to the ceiling joists or setting up an isolation zone to limit the movement of the crane or cranes in the area where the worker is tied off. |
Heavy loads, dangerous machinery, work at height… the industrial environment can feel like a zone of constant hazards! And since the 2019 change to the regulation on the maximum height allowed without fall protection, measuring the permitted height is no longer enough: many companies now have to deal with this reality on a daily basis.
So when a worker has to operate at height, how do you get them to the location safely? How do you protect them from a fall? And what does the regulation say? In recent years, two questions have come up more and more often in my conversations with our clients:
- Can an overhead crane be used to lift a worker from a work platform (often called cage or basket)?
- Can an overhead crane structure be used to suspend a cable reel to protect a worker from a fall (i.e. as an anchor point for a fall arrest)?
Excellent questions, and entirely legitimate! After all, factory ceilings are full of overhead cranes capable of lifting tons safely. So why not take advantage of them?
At Premium, we analyzed the standards to give you the most accurate information possible. After reading this article, you'll know whether you can lift a worker with an overhead crane, whether you can use it as a lifeline and, if so, what conditions you need to meet. No need to become a regulations expert: you'll be able to act with confidence when an employee has to work at height in your plant.
Let's start with the first question: can you use an overhead crane to lift a worker?
Why is it forbidden to use an overhead crane to lift a worker?
It is indeed not permitted to lift a worker with an overhead crane. Why not?
Firstly, because the overhead crane was not designed for this use (article 260 of the RROHS). And even if steps were taken, no hoist manufacturer authorizes its products to lift a person.
So, what is the recommended solution? Use equipment designed for this purpose, such as lifts or aerial work platforms.
Although it’s not possible to use an overhead crane to lift a person, is it possible to attach a worker to the structure of an overhead crane as fall protection?
Mobile cranes : different regulations
Since it is possible to lift a person with a mobile crane (under certain conditions), confusion reigns on some construction sites. Some people think they can do the same thing with overhead cranes. But in fact, these 2 types of equipment are governed by completely different standards.
How can I safely use an overhead crane as a fall arrest?
This involves attaching the worker’s harness to a cable reel which is connected to an anchor point on the overhead crane structure, i.e. the crane frame. Such a system is generally referred to as a “fall arrest”. So, is it allowed to install a fall arrest on an overhead crane in this way?
Short answer : YES, but under certain conditions. Let’s take a look at the requirements and steps involved.
Mandatory conditions for using an overhead crane as a fall arrest :
- These three elements must be completed and approved by an engineer:
- authorization to use the overhead crane for this purpose
- determination of an anchorage point designed for this purpose
- documentation of an operating procedure -
A lockout procedure must be in place: the overhead crane must be at zero energy during use of the lifeline. (See box below.)
If applicable, any adjacent overhead crane must be prevented from coming into contact with the overhead crane in question, generally through a lockout procedure. (See other available solutions below.)
- The employer must conduct a risk assessment, establish a rescue procedure, and train the workers.
- Once the risk assessment has been completed, it will be possible to determine the fall arrest connecting subsystem and the harness to be attached to the anchorage point located on the overhead crane.
As we can see, it’s not easy to use an overhead crane as a fall arrest. So, are there any alternatives? If not, what solutions can simplify the process?
What is a 0-energy overhead crane?
Some might think that pressing the red stop-reset button (often called the emergency stop) is enough to bring an overhead crane to zero energy. In reality, that’s not sufficient.
Setting to zero energy means cutting off all energy sources, notably the electrical supply, which can only be done through a lockout procedure.
Keeping the remote control on you does not replace a proper lockout procedure. Locking out the remote control does not bring the crane to a zero energy state.
Floor-level lockout devices provide effective safety without blocking other overhead cranes or disrupting operations. See the article : Maintenance zone: protect your workers while optimizing your operations!
Alternatives and solutions for a simple and safe fall arrest system!
Sometimes you just have to look at things differently to find a simpler solution. For example, instead of using an overhead crane, can you hang directly from the ceiling structure? Of course, the first step is to check that the joints can support a fall arrest. But if not, they can be reinforced. However, overhead cranes must be prevented from approaching the fall arrests while in use. What solutions are available for this?
Whether you’re hooked onto the overhead crane or the ceiling beams, solutions are available to prevent overhead cranes from approaching the fall arrests. For example, an isolation zone can be installed. What is it? It’s a system of conductor bars that electrically isolate the section of runway where the fall arrests are located, ensuring it is at 0 energy during use. It is also possible to install an interlock system. How does it work? When the harness of the worker who will be working at height is accessed, a system automatically deactivates the energy of the section to prevent adjacent overhead cranes from reaching the work area. This ensures the safety of the worker using a fall arrest in an area with overhead cranes.
Some companies specialize in fall arrest systems, beam reinforcement and interlock systems (For example, see the page of our sister company SIP “Worker safety: Fall arrest systems near overhead cranes“).
Safety: an important issue in the world of lifting!
As we have seen, the use of an overhead crane to lift a worker is prohibited. However, the use of an overhead crane structure as an anchor point for a fall arrest system may be possible under very strict conditions. In all cases, put your workers’ safety first! Workers’ lives and health are far too important to improvise! And when in doubt, consult a lifting specialist who is familiar with current standards. He or she will certainly be able to suggest solutions adapted to your needs, as there are many technologies available today for lifting.
Where to start?
Want to keep your workers safe when working at height, but wondering where to start? Here are 3 fall arrest installation situations we can help you with :
- To install a fall arrest as part of a new overhead crane project or manufactured by Premium, contact your lifting specialist. For example, you can fill in the form at the bottom of this page, and a representative will be happy to propose safe solutions.
- When installing a fall arrest on equipment not manufactured by Premium, we recommend that you first consult an engineer, as this is the first step. We can refer you to a partner if required. Simply specify this by filling in the request form at the bottom of the page.
- To install a fall arrest on a building structure, please contact our sister compagny Premium Industrial Structures.
In the end, the solution is quite simple! Let your lifting specialist guide you in your safety choices when your overhead cranes are involved. Find a good partner who can advise you based on current standards and regulations.
FAQ
Is locking out the pendant control alone enough to use an overhead crane as a lifeline?
No. Locking out the pendant control alone does not bring the overhead crane to a zero energy state. Only a lockout procedure that cuts the crane's electrical power supply, for example at the conductor bars, achieves the required zero energy state.
Can a worker attach directly to the overhead crane's hook for fall protection?
No. The large majority of hoist manufacturers do not accept their product being used as an anchor point for a lifeline. Section 260 of the RSST is clear: lifting a worker with a lifting device not designed for that purpose is prohibited. Alternatives exist, such as an anchor trolley on the crane's structure or a ceiling-mounted lifeline with a descent system.
Do anti-collision systems or limit switches between two cranes protect a worker attached to an overhead crane?
No. These systems only cut the crane's motion control, not its power supply. The crane is therefore not at zero energy, and these devices do not replace a lockout procedure.
Can an overhead crane or hoist be used as rescue equipment in a confined space?
No. The lifting force and speed of an overhead crane or hoist are not suited to raising a worker, which could cause serious injury if the worker became caught during the ascent. The crane's structure can, however, serve as an anchor point for a rescue system, under the same strict conditions as a lifeline: engineer authorization, a zero energy lockout procedure, and a risk assessment.
