Excavator Lifting Safety Guide: Follow These Guidelines to Avoid Accidents
Posted: Apr 7th, '25, 23:15
Excavator hoisting safety guide: strictly follow these guidelines to eliminate potential accidents
Excavator hoisting operations frequently occur in various engineering construction projects, which are essential for equipment transportation, installation and other work. However, excavators are large in size and heavy in weight. Once a mistake occurs during the hoisting process, it is very likely to cause a serious safety accident, resulting in casualties and property losses. Therefore, strictly following the safety guidelines for excavator hoisting has become the key to ensuring smooth operations and eliminating potential accidents.
1. Comprehensive preparation before hoisting
(I) Site survey and planning
Geological condition assessment: Before the excavator hoisting operation, the first task is to conduct a detailed survey of the hoisting site. Use professional tools to detect the bearing capacity of the ground and check whether there are factors that affect stability, such as soft soil layers and underground cavities. For areas with insufficient bearing capacity, reinforcement treatment is required in advance, such as laying steel plates and pouring concrete cushions. For example, in a certain city subway construction project, due to the high groundwater level and soft ground in some areas, the construction team laid a 20 cm thick steel plate before hoisting the excavator, which effectively dispersed the weight of the crane and excavator and ensured the safety of the operation.
Spatial planning and obstacle clearance: comprehensively review the spatial layout of the hoisting site and measure the distance between the surrounding buildings, overhead cables, trees and other obstacles and the hoisting area. Plan the driving routes and parking positions of the excavator and crane in advance to ensure that there is enough space for rotation, lifting and other operations. Clean up the debris and waste in the site, remove temporary facilities that affect the hoisting operation, and open up an unobstructed space for the hoisting operation.
Set up warning signs: set up obvious warning signs around the hoisting operation area, such as "Hoisting operation, no entry" and "Dangerous area, please do not approach" and other warning signs, and set up cordons. Arrange special personnel to be responsible for the guard to prevent unrelated personnel from entering the operation area to avoid accidents caused by intrusion.
(II) Equipment inspection and maintenance
Key points for excavator inspection: Conduct a comprehensive inspection of the excavator to ensure that it is in good operating condition. Focus on checking whether the working devices of the excavator, such as the bucket, boom, and dipper rod, are deformed or cracked; the slewing flexibility and braking reliability of the slewing mechanism; the wear of the crawler or tires of the walking system, and whether the braking performance is normal. At the same time, check whether the hydraulic system of the excavator has leakage and whether the operating handles are flexible and effective. Any potential fault may cause serious problems during the lifting process and must be repaired in time.
Details of crane inspection: As the core equipment for excavator lifting, the performance of the crane is directly related to the safety of lifting. Check whether the crane hook is worn, deformed or cracked, and whether the anti-drop device of the hook is intact. Carefully check the wear and broken wire of the wire rope. According to regulations, when the number of broken wires in one lay of the wire rope exceeds 5% of the total, it must be replaced in time. Check the braking device of the crane, including the driving brake, slewing brake and variable amplitude brake, to ensure that the braking is sensitive and reliable. In addition, the hydraulic system and electrical system of the crane need to be checked to ensure that all components operate normally and the instrument display is accurate.
Inspection of lifting equipment and auxiliary equipment: Strictly check the lifting equipment used to connect the excavator and the crane, such as slings and shackles. Check whether the slings are broken, worn, corroded, etc. The safety factor of the sling must meet the requirements of relevant standards. Check whether the threads of the shackles are intact, whether they rotate flexibly, and whether there are signs of deformation. At the same time, prepare necessary auxiliary equipment, such as pads, wedges, etc., and check whether their quality is qualified to ensure that they can play their due role during the lifting process.
2. Safe operation during lifting
(I) Correctly select the lifting point and connection method
Reasonably determine the position of the lifting point: Select a suitable lifting point according to the structural characteristics and center of gravity of the excavator. Generally speaking, the lifting point of the excavator is located at the slewing platform, the root of the boom, etc. When determining the lifting point, it is necessary to ensure that the lifting points are evenly distributed so that the excavator can maintain balance during the lifting process. For large excavators, it may be necessary to set up multiple lifting points. Through calculation and actual measurement, the position of each lifting point is accurately determined to ensure that all parts of the excavator are evenly stressed during lifting, and to avoid deformation or falling of the excavator due to uneven stress.
Reliable connection method: Use a sling that meets safety standards to firmly connect the hook to the lifting point of the excavator. During the connection process, ensure that the angle of the sling is appropriate, generally not more than 90 degrees, to prevent the sling from being broken due to excessive tension. Use the correct bundling method, such as the bottom bundling method, the ring bundling method, etc., and choose the most appropriate method according to the shape of the excavator and the position of the lifting point. When using a shackle to connect the sling to the excavator, ensure that the pin of the shackle is installed in place and tighten the nut to prevent the shackle from loosening and falling off during the lifting process.
Trial lifting is essential: Before officially lifting the excavator, a trial lifting must be carried out. Slowly lift the hook so that the excavator is about 10-20 cm off the ground and stay for 2-3 minutes. During this period, carefully observe the stability of the crane, the connection between the hook and the sling, and whether the posture of the excavator is normal. At the same time, check whether there is any settlement on the ground. If any abnormality is found, stop the trial lifting immediately. After the problem is checked and solved, the trial lifting can be carried out again until the trial lifting is successful. After confirming that everything is normal, the formal lifting operation can be carried out.
(II) Standardized operation process
Lifting speed and stability control: During the formal lifting, the operator of the crane should slowly and evenly lift the hook to avoid sudden acceleration or deceleration to prevent the excavator from shaking due to inertia. Control the rising speed of the excavator, which should generally not exceed 0.5 m/s, to ensure a smooth lifting process. During the rising process of the excavator, pay close attention to the various instrument parameters of the crane, such as lifting weight, torque, etc., and overload lifting is strictly prohibited. Once an abnormal instrument parameter is found, stop lifting immediately and check the cause.
Precautions for slewing and amplitude operation: When the excavator rises to a certain height, it is necessary to perform a slewing operation to transfer the excavator to the top of the target position. During the slewing process, keep the slewing speed uniform and avoid sharp turns. At the same time, closely observe the distance between the excavator and the surrounding obstacles to ensure that the safety distance is not less than 1 meter. When performing the boom operation of the crane, the angle of the crane arm should be reasonably adjusted according to the position and height of the excavator. Attention should also be paid to the stability of the operation to prevent the excavator from shaking or instability due to too fast boom changes.
Lowering and positioning operation: After the excavator is hoisted above the target position, start to slowly lower the hook. During the lowering process, the speed should also be kept uniform, and close attention should be paid to the excavator's descending posture to ensure that it descends smoothly. When the excavator approaches the ground, it should be operated more carefully to prevent the excavator from colliding violently with the ground. After the excavator lands, do not rush to release the sling. Check again whether the position of the excavator is accurate and whether it is placed stably in the predetermined position. After confirmation, the connection between the sling and the excavator can be released.
3. Personnel safety management
(I) Professional personnel deployment and qualification requirements
Operator qualification review: Crane operators and excavator operators involved in excavator hoisting operations must hold relevant special operation operation certificates, and the certificates must be valid. Regularly review the qualifications of operators to ensure that they have the corresponding operating skills and experience. It is strictly forbidden for unlicensed personnel or personnel with expired certificates to participate in hoisting operations to ensure the safety of operations from the source of personnel.
The importance of command personnel: Equip professional command personnel, who should have rich experience in commanding hoisting operations, be familiar with the operating performance of excavators and cranes, and be able to issue command signals accurately and clearly. The command personnel and operators should maintain good communication and use standard command signals, such as gestures, whistles, etc., to ensure that the operators can accurately understand the command intentions and avoid operational errors due to poor communication.
Setting up safety supervisors: Set up special safety supervisors at the hoisting operation site to supervise whether the entire hoisting operation process complies with safety regulations. Safety supervisors should always pay attention to the safety conditions at the work site, and promptly discover and correct unsafe behaviors of operators, such as illegal operations and violation of warning signs. Once a safety hazard is discovered, an order to stop the operation should be issued immediately, and the operation can only be continued after appropriate measures are taken to eliminate the hazard.
(II) Personnel training and safety awareness improvement
Regular safety training: Regularly organize safety training for personnel involved in excavator hoisting operations. The training content includes safe operating procedures for hoisting operations, accident case analysis, emergency response methods, etc. Through training, the safety awareness of personnel is continuously strengthened, and their operating skills and ability to deal with emergencies are improved. After the training, the personnel participating in the training should be assessed, and they can continue to participate in the hoisting operation only after passing the assessment.
Safety briefing work: Before each excavator hoisting operation, a detailed safety briefing must be conducted. The project leader or safety manager shall explain the tasks, processes, safety precautions, etc. of this hoisting operation to the operators, commanders, safety supervisors and other relevant personnel. Ensure that every person involved in the operation clearly understands the risk points and countermeasures during the operation, so that safety awareness is deeply rooted in the hearts of the people and implemented in every operation link.
Equipment and use of personal protective equipment: Equip personnel involved in excavator hoisting operations with complete personal protective equipment, such as helmets, safety belts, safety shoes, protective gloves, etc. Operators are required to wear and use personal protective equipment correctly during the operation, and it is strictly forbidden to not wear helmets, not wear safety belts and other violations. Strengthen the inspection and maintenance of personal protective equipment to ensure its good protective performance and provide effective protection for the personal safety of operators.
IV. Emergency measures for emergencies
(I) Formulate emergency plans
Comprehensiveness of the plan content: Combined with the characteristics of excavator hoisting operations and the actual situation on site, formulate a detailed and comprehensive emergency plan. The emergency plan should include possible emergencies, such as crane failure, excavator fall, casualties, etc., and formulate specific response measures and operating procedures for each situation. Clarify the responsibilities and division of labor of each emergency rescue team, such as emergency rescue team, medical rescue team, logistics support team, etc., to ensure that each team can carry out rescue work quickly and orderly when an emergency occurs.
Regular emergency drills: Regularly organize emergency drills for excavator hoisting operations to simulate various possible emergencies and test the feasibility and effectiveness of emergency plans. Through emergency drills, let the personnel involved in the operation become familiar with the emergency rescue process and improve their emergency response and coordination capabilities. After the drill, summarize and evaluate the drill process, revise and improve the emergency plan based on the problems found in the drill, and continuously improve the practicality of the emergency plan.
(II) Emergency rescue equipment and material reserves
Equipment and materials are fully equipped: reserve necessary emergency rescue equipment and materials at the excavator hoisting site, such as fire extinguishers, first aid kits, stretchers, crane rescue tools, etc. Ensure that the number of emergency rescue equipment and materials is sufficient and the performance is good, and regularly check and maintain them to ensure that they can be used normally in the event of an emergency. For example, regularly check whether the pressure of the fire extinguisher is normal and whether the medicines in the first aid kit are expired.
Establish a rapid response mechanism: Establish a rapid response mechanism for emergencies to ensure that the emergency plan can be quickly activated and emergency rescue forces can be organized for rescue as soon as an accident occurs. Clarify the contact information for emergency rescue, such as setting up a special emergency rescue phone number and ensuring that the phone is unobstructed. Post emergency rescue flowcharts and contact numbers in prominent locations on site to facilitate operators to quickly obtain rescue information in emergency situations.
The safety of excavator hoisting operations is a top priority in engineering construction. By making comprehensive preparations before hoisting, strictly observing the safety operating specifications during hoisting, strengthening personnel safety management, and formulating comprehensive emergency measures, it is possible to effectively eliminate potential accidents, ensure the safety and smooth progress of excavator hoisting operations, and provide solid guarantees for the smooth progress of engineering construction. In actual operations, it is imperative to keep the safety guidelines in mind and implement them in every operational detail to effectively protect the safety of personnel and property.
Excavator hoisting operations frequently occur in various engineering construction projects, which are essential for equipment transportation, installation and other work. However, excavators are large in size and heavy in weight. Once a mistake occurs during the hoisting process, it is very likely to cause a serious safety accident, resulting in casualties and property losses. Therefore, strictly following the safety guidelines for excavator hoisting has become the key to ensuring smooth operations and eliminating potential accidents.
1. Comprehensive preparation before hoisting
(I) Site survey and planning
Geological condition assessment: Before the excavator hoisting operation, the first task is to conduct a detailed survey of the hoisting site. Use professional tools to detect the bearing capacity of the ground and check whether there are factors that affect stability, such as soft soil layers and underground cavities. For areas with insufficient bearing capacity, reinforcement treatment is required in advance, such as laying steel plates and pouring concrete cushions. For example, in a certain city subway construction project, due to the high groundwater level and soft ground in some areas, the construction team laid a 20 cm thick steel plate before hoisting the excavator, which effectively dispersed the weight of the crane and excavator and ensured the safety of the operation.
Spatial planning and obstacle clearance: comprehensively review the spatial layout of the hoisting site and measure the distance between the surrounding buildings, overhead cables, trees and other obstacles and the hoisting area. Plan the driving routes and parking positions of the excavator and crane in advance to ensure that there is enough space for rotation, lifting and other operations. Clean up the debris and waste in the site, remove temporary facilities that affect the hoisting operation, and open up an unobstructed space for the hoisting operation.
Set up warning signs: set up obvious warning signs around the hoisting operation area, such as "Hoisting operation, no entry" and "Dangerous area, please do not approach" and other warning signs, and set up cordons. Arrange special personnel to be responsible for the guard to prevent unrelated personnel from entering the operation area to avoid accidents caused by intrusion.
(II) Equipment inspection and maintenance
Key points for excavator inspection: Conduct a comprehensive inspection of the excavator to ensure that it is in good operating condition. Focus on checking whether the working devices of the excavator, such as the bucket, boom, and dipper rod, are deformed or cracked; the slewing flexibility and braking reliability of the slewing mechanism; the wear of the crawler or tires of the walking system, and whether the braking performance is normal. At the same time, check whether the hydraulic system of the excavator has leakage and whether the operating handles are flexible and effective. Any potential fault may cause serious problems during the lifting process and must be repaired in time.
Details of crane inspection: As the core equipment for excavator lifting, the performance of the crane is directly related to the safety of lifting. Check whether the crane hook is worn, deformed or cracked, and whether the anti-drop device of the hook is intact. Carefully check the wear and broken wire of the wire rope. According to regulations, when the number of broken wires in one lay of the wire rope exceeds 5% of the total, it must be replaced in time. Check the braking device of the crane, including the driving brake, slewing brake and variable amplitude brake, to ensure that the braking is sensitive and reliable. In addition, the hydraulic system and electrical system of the crane need to be checked to ensure that all components operate normally and the instrument display is accurate.
Inspection of lifting equipment and auxiliary equipment: Strictly check the lifting equipment used to connect the excavator and the crane, such as slings and shackles. Check whether the slings are broken, worn, corroded, etc. The safety factor of the sling must meet the requirements of relevant standards. Check whether the threads of the shackles are intact, whether they rotate flexibly, and whether there are signs of deformation. At the same time, prepare necessary auxiliary equipment, such as pads, wedges, etc., and check whether their quality is qualified to ensure that they can play their due role during the lifting process.
2. Safe operation during lifting
(I) Correctly select the lifting point and connection method
Reasonably determine the position of the lifting point: Select a suitable lifting point according to the structural characteristics and center of gravity of the excavator. Generally speaking, the lifting point of the excavator is located at the slewing platform, the root of the boom, etc. When determining the lifting point, it is necessary to ensure that the lifting points are evenly distributed so that the excavator can maintain balance during the lifting process. For large excavators, it may be necessary to set up multiple lifting points. Through calculation and actual measurement, the position of each lifting point is accurately determined to ensure that all parts of the excavator are evenly stressed during lifting, and to avoid deformation or falling of the excavator due to uneven stress.
Reliable connection method: Use a sling that meets safety standards to firmly connect the hook to the lifting point of the excavator. During the connection process, ensure that the angle of the sling is appropriate, generally not more than 90 degrees, to prevent the sling from being broken due to excessive tension. Use the correct bundling method, such as the bottom bundling method, the ring bundling method, etc., and choose the most appropriate method according to the shape of the excavator and the position of the lifting point. When using a shackle to connect the sling to the excavator, ensure that the pin of the shackle is installed in place and tighten the nut to prevent the shackle from loosening and falling off during the lifting process.
Trial lifting is essential: Before officially lifting the excavator, a trial lifting must be carried out. Slowly lift the hook so that the excavator is about 10-20 cm off the ground and stay for 2-3 minutes. During this period, carefully observe the stability of the crane, the connection between the hook and the sling, and whether the posture of the excavator is normal. At the same time, check whether there is any settlement on the ground. If any abnormality is found, stop the trial lifting immediately. After the problem is checked and solved, the trial lifting can be carried out again until the trial lifting is successful. After confirming that everything is normal, the formal lifting operation can be carried out.
(II) Standardized operation process
Lifting speed and stability control: During the formal lifting, the operator of the crane should slowly and evenly lift the hook to avoid sudden acceleration or deceleration to prevent the excavator from shaking due to inertia. Control the rising speed of the excavator, which should generally not exceed 0.5 m/s, to ensure a smooth lifting process. During the rising process of the excavator, pay close attention to the various instrument parameters of the crane, such as lifting weight, torque, etc., and overload lifting is strictly prohibited. Once an abnormal instrument parameter is found, stop lifting immediately and check the cause.
Precautions for slewing and amplitude operation: When the excavator rises to a certain height, it is necessary to perform a slewing operation to transfer the excavator to the top of the target position. During the slewing process, keep the slewing speed uniform and avoid sharp turns. At the same time, closely observe the distance between the excavator and the surrounding obstacles to ensure that the safety distance is not less than 1 meter. When performing the boom operation of the crane, the angle of the crane arm should be reasonably adjusted according to the position and height of the excavator. Attention should also be paid to the stability of the operation to prevent the excavator from shaking or instability due to too fast boom changes.
Lowering and positioning operation: After the excavator is hoisted above the target position, start to slowly lower the hook. During the lowering process, the speed should also be kept uniform, and close attention should be paid to the excavator's descending posture to ensure that it descends smoothly. When the excavator approaches the ground, it should be operated more carefully to prevent the excavator from colliding violently with the ground. After the excavator lands, do not rush to release the sling. Check again whether the position of the excavator is accurate and whether it is placed stably in the predetermined position. After confirmation, the connection between the sling and the excavator can be released.
3. Personnel safety management
(I) Professional personnel deployment and qualification requirements
Operator qualification review: Crane operators and excavator operators involved in excavator hoisting operations must hold relevant special operation operation certificates, and the certificates must be valid. Regularly review the qualifications of operators to ensure that they have the corresponding operating skills and experience. It is strictly forbidden for unlicensed personnel or personnel with expired certificates to participate in hoisting operations to ensure the safety of operations from the source of personnel.
The importance of command personnel: Equip professional command personnel, who should have rich experience in commanding hoisting operations, be familiar with the operating performance of excavators and cranes, and be able to issue command signals accurately and clearly. The command personnel and operators should maintain good communication and use standard command signals, such as gestures, whistles, etc., to ensure that the operators can accurately understand the command intentions and avoid operational errors due to poor communication.
Setting up safety supervisors: Set up special safety supervisors at the hoisting operation site to supervise whether the entire hoisting operation process complies with safety regulations. Safety supervisors should always pay attention to the safety conditions at the work site, and promptly discover and correct unsafe behaviors of operators, such as illegal operations and violation of warning signs. Once a safety hazard is discovered, an order to stop the operation should be issued immediately, and the operation can only be continued after appropriate measures are taken to eliminate the hazard.
(II) Personnel training and safety awareness improvement
Regular safety training: Regularly organize safety training for personnel involved in excavator hoisting operations. The training content includes safe operating procedures for hoisting operations, accident case analysis, emergency response methods, etc. Through training, the safety awareness of personnel is continuously strengthened, and their operating skills and ability to deal with emergencies are improved. After the training, the personnel participating in the training should be assessed, and they can continue to participate in the hoisting operation only after passing the assessment.
Safety briefing work: Before each excavator hoisting operation, a detailed safety briefing must be conducted. The project leader or safety manager shall explain the tasks, processes, safety precautions, etc. of this hoisting operation to the operators, commanders, safety supervisors and other relevant personnel. Ensure that every person involved in the operation clearly understands the risk points and countermeasures during the operation, so that safety awareness is deeply rooted in the hearts of the people and implemented in every operation link.
Equipment and use of personal protective equipment: Equip personnel involved in excavator hoisting operations with complete personal protective equipment, such as helmets, safety belts, safety shoes, protective gloves, etc. Operators are required to wear and use personal protective equipment correctly during the operation, and it is strictly forbidden to not wear helmets, not wear safety belts and other violations. Strengthen the inspection and maintenance of personal protective equipment to ensure its good protective performance and provide effective protection for the personal safety of operators.
IV. Emergency measures for emergencies
(I) Formulate emergency plans
Comprehensiveness of the plan content: Combined with the characteristics of excavator hoisting operations and the actual situation on site, formulate a detailed and comprehensive emergency plan. The emergency plan should include possible emergencies, such as crane failure, excavator fall, casualties, etc., and formulate specific response measures and operating procedures for each situation. Clarify the responsibilities and division of labor of each emergency rescue team, such as emergency rescue team, medical rescue team, logistics support team, etc., to ensure that each team can carry out rescue work quickly and orderly when an emergency occurs.
Regular emergency drills: Regularly organize emergency drills for excavator hoisting operations to simulate various possible emergencies and test the feasibility and effectiveness of emergency plans. Through emergency drills, let the personnel involved in the operation become familiar with the emergency rescue process and improve their emergency response and coordination capabilities. After the drill, summarize and evaluate the drill process, revise and improve the emergency plan based on the problems found in the drill, and continuously improve the practicality of the emergency plan.
(II) Emergency rescue equipment and material reserves
Equipment and materials are fully equipped: reserve necessary emergency rescue equipment and materials at the excavator hoisting site, such as fire extinguishers, first aid kits, stretchers, crane rescue tools, etc. Ensure that the number of emergency rescue equipment and materials is sufficient and the performance is good, and regularly check and maintain them to ensure that they can be used normally in the event of an emergency. For example, regularly check whether the pressure of the fire extinguisher is normal and whether the medicines in the first aid kit are expired.
Establish a rapid response mechanism: Establish a rapid response mechanism for emergencies to ensure that the emergency plan can be quickly activated and emergency rescue forces can be organized for rescue as soon as an accident occurs. Clarify the contact information for emergency rescue, such as setting up a special emergency rescue phone number and ensuring that the phone is unobstructed. Post emergency rescue flowcharts and contact numbers in prominent locations on site to facilitate operators to quickly obtain rescue information in emergency situations.
The safety of excavator hoisting operations is a top priority in engineering construction. By making comprehensive preparations before hoisting, strictly observing the safety operating specifications during hoisting, strengthening personnel safety management, and formulating comprehensive emergency measures, it is possible to effectively eliminate potential accidents, ensure the safety and smooth progress of excavator hoisting operations, and provide solid guarantees for the smooth progress of engineering construction. In actual operations, it is imperative to keep the safety guidelines in mind and implement them in every operational detail to effectively protect the safety of personnel and property.