Communication Breakdown During a Blind Pick
A bridge crane operator in a cab must pick a 3 t bundle of steel from a storage bay that is hidden behind a rack of tall pallets. The rigger on the floor is using hand signals, but the operator cannot see the rigger's hands from the cab because of the rack. The rigger has a radio, but the battery is flat and there is no spare. The rigger proposes to stand on the bundle and guide it by voice, shouting over the crane noise. Two other workers are working in the adjacent bay, and a forklift is moving nearby. The lift is needed to load a truck that is waiting.
1. What communication and visibility problems exist, and why is the proposed solution unsafe?
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Problems:
- No line of sight between operator and rigger; the rack blocks the view of the load and the rigger.
- No working radio, so the only channel is shouting over crane and forklift noise, which is unreliable and easily misheard.
- Rigger standing on the load is unsafe: the load may move or the rigger may fall; a person must never ride the load or stand on it during a lift.
- Adjacent workers and forklift add distractions and a chance of collision or struck-by injury.
- Time pressure from the waiting truck pushes toward shortcuts.
The proposed solution removes the operator's ability to see the load and the rigger, and puts the rigger in a fall and crush hazard. A misheard command could raise, lower or travel the wrong way with a 3 t bundle.
2. What controls should be put in place before the pick proceeds?
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Controls:
- Restore communication. Fit a charged radio to the rigger, or use a second rigger as a relay with a clear view, or reposition the crane so the operator has line of sight. Do not rely on shouting.
- Agree signals and commands before the lift, including an all-stop word and a repeat-back protocol.
- One person in charge - only the designated rigger gives signals; others relay only if authorised.
- Clear the area. Stop the forklift and move adjacent workers out of the exclusion zone, or barricade the bay.
- Rigger position. The rigger stands at a safe distance with a clear view of the load and the operator, never on the load.
- Trial lift. Lift 100-150 mm, confirm the bundle is balanced and the rigging is correct, then proceed.
- If communication fails at any point, the operator stops and holds until communication is restored.
If these cannot be met, the lift is deferred; the waiting truck is not a reason to lift blind.