Signalling and Communication
Effective signalling prevents accidents. The signaller must be competent, have a clear and unobstructed view of the load and the operator (or reliable communication such as radio), be clearly identifiable (hi-vis, agreed role marker), and use the agreed signal set. Standard hand signals cover stop, raise, lower, slew left/right, travel, dog everything, and emergency stop. The emergency stop signal must be unmistakable and obeyed immediately by the operator. Where hand signals are not possible, use radio with clear, brief phrases and a recognised protocol; confirm understanding and repeat back critical instructions. Only one signaller should direct the operator at a time to avoid conflicting commands.
Traps: multiple people signalling; using ambiguous or non-standard signals; assuming the operator can see you when they cannot; and failing to agree a communication method at the briefing. Questions often test the 'stop' signal - anyone can give it, and the operator must stop. Also watch for the signaller standing in a dangerous position to get a view, or losing sight of the load mid-lift (the lift should stop until communication is restored).
Rule of thumb: one signaller, one set of agreed signals, clear line of sight or radio, and anyone can stop the job. If you lose sight or contact, stop.
Lifting Operation Planning and Site Coordination
Planning turns a lift into a controlled, predictable task. The appointed person produces a lift plan based on a risk assessment: load weight and dimensions, centre of gravity, lift points, crane selection and configuration, load chart checks, ground conditions and outrigger spread, proximity hazards (power lines, excavations, other trades), exclusion zones, weather limits, communication method, and emergency arrangements. Routine lifts may follow a generic plan; complex or critical lifts need a specific, documented plan and often a trial lift. Coordination with other site activities is essential - cranes and excavators share space, and pedestrians must be kept out of the zone.
Traps: treating a lift plan as a one-off document that never changes; failing to reassess when conditions change (ground, weather, personnel, load); and assuming a load chart figure applies at any radius or configuration - capacity falls as radius increases, and configurations (boom length, counterweight) change ratings. Also watch for planning that ignores the rescue plan or the route the load will travel.
Worked example: a crane rated 10 tonnes at 10 m radius may be rated only 6 tonnes at 14 m. If the load is 7 tonnes, the lift is not permitted at 14 m even though the crane 'can lift 10'. Always check the chart at the actual radius and configuration, and include the weight of the rigging.
Rule of thumb: plan the lift, brief the team, control the zone, and reassess whenever anything changes.