How to Improve Crane Safety with Better Weather Intelligence

Cranes are fundamental to our modern way of life. Our city skyscrapers, global supply chain, and technology powered by critical minerals simply wouldn’t be possible without the work of crane operators around the world each day.

With that said, the same cranes that support our economy can easily become dangerous for people, structures, and goods in the wrong storm. That’s why getting crane weather safety right is key for operations leaders in a variety of settings, from downtown construction to deep sea mining.

Moving forward, we’ll explore…

• How weather creates safety hazards for cranes and crane operators
• What OSHA compliance requires in terms of wind monitoring for cranes
• How better weather monitoring and forecasting increase crane safety
• How lift directors and operations leaders can get the weather data they need to protect equipment, operators, materials, and everybody else

How does severe weather impact crane safety?

Cranes tend to be present in environments where weather-dependent work is already taking place: construction sites, shipping and rail yards, mines, and so on. While cranes are fundamental to executing the work that keeps our world going, they also create additional challenges due to their size, design, and function.

Even though extreme temperatures, lightning strikes, and precipitation can all affect a crane in unsafe ways, wind is the primary threat. OSHA is specifically concerned about wind when it comes to cranes because wind can rapidly turn perfectly safe lift operations into a situation that’s dangerous for the operator, the load, and anyone nearby.

You don’t need a great imagination to understand why wind and cranes don’t mix. Cranes and derricks are large structures that, while powerful, use simple machines so that they can move massive loads while remaining relatively mobile. The same design that makes them work also makes them vulnerable to getting pushed around by the wind.

When strong gusts of wind blow on a crane bearing a load, it can cause the load to swing, potentially impacting nearby people, buildings, equipment, and even the stability of the crane itself.

That’s why halting crane operations during dangerously windy conditions is essential.

What do lift directors need to improve crane safety?

Let’s take a look at what occupational safety regulations require at minimum and then imagine the ideal system from there.

According to OSHA section 1917.45, which governs crane use at marine terminals:

“…Each rail-mounted bridge and portal crane located outside of an enclosed structure shall be fitted with an operable wind-indicating device. The wind-indicating device shall provide a visible or audible warning to alert the operator of high wind conditions. The warning shall be transmitted whenever the following circumstances are present: (1) When wind velocity reaches warning speed, not exceeding the crane manufacturer’s recommendations; and (2) when wind velocity reaches the shutdown speed, not exceeding the crane manufacturer's recommendations, at which work is to be stopped and the crane secured…

When the wind reaches the crane’s warning speed, gantry travel should be stopped, and the crane shall be readied for shutdown. When the wind reaches the crane’s shutdown speed, any portion of the crane spanning or partially spanning a vessel shall be moved clear of the vessel if safe to do so, and the crane shall be secured against travel, using all available means of securing. The employer shall monitor local weather conditions by subscribing to a local weather service or using equally effective means.”

OSHA section 1926.1425, which governs tower cranes in construction contexts provides even less guidance, stating:

Wind speed: Wind must not exceed the speed recommended by the manufacturer or, where manufacturer does not specify this information, the speed determined by a qualified person…

Wind speed indicator: A device must be provided to display the wind speed and must be mounted above the upper rotating structure on tower cranes. On self erecting cranes, it must be mounted at or above the jib level. Temporary alternative measures: Use of wind speed information from a properly functioning indicating device on another tower crane on the same site, or a qualified person estimates the wind speed.

Based on those guidelines, the minimum for compliance is a device that monitors wind around the crane in real time and directly alerts the operator when warning and shutdown thresholds are met. That means a compliant approach could still have numerous dangerous gaps in it. For example…

• What about situations where multiple operators are using cranes near each other that may be reporting a range of different readings? What does safety and coordination between them look like?
• The burden of making the right decision is almost entirely on the operator. Other than posting an instructional placard, the lift director and site safety supervisor have no role in the safety process.
• If the crane operator is the only person who sees real-time wind data, how can you coordinate a timely operational response across the rest of the team?
• What happens when strong winds come “out of nowhere” and securing the crane immediately becomes dangerous unto itself?
• What if someone is fully qualified when it comes to equipment and safety training but is a lousy estimator of wind speed?

…In any of those scenarios, a crane wind monitoring system could be in full compliance with §1917.45 or §1926.1425 and still leave people, goods, and equipment vulnerable to catastrophic harm. Let’s take a look at what a system that fully honors the spirit of the regulations while also taking a business-minded approach looks like…

Improving visibility and context for crane wind data

At AEM, we recommend the u[sonic] WS7 weather sensor for crane wind monitoring applications because:

• It measures wind speed and direction in real time with no moving parts, so it requires less maintenance, and there’s no data degradation or device failure as cups and bearings wear, as with a traditional anemometer
• In addition to providing programmable alarms for compliance with OSHA §1917.45, §1926.1425, and related regulations, the sensor offers additional weather intelligence (temperature, humidity, UV radiation) that can inform further alarm/notification thresholds for worker and site safety
• A variety of key stakeholders – crane operators, ops managers, safety supervisors, lift directors, etc. – can review data from the sensor simultaneously and receive notifications through AEM Elements™ 360
• The WS7 is incredibly easy to install and designed to withstand winds up to 140 miles per hour (65 m/s)

Using the WS7 and AEM Elements 360, shipping terminals, construction teams, and anybody else using a crane can build a broader culture of safety and enable truly weather-ready operations. In addition to the on-site data from the WS7, weather forecasts available within the AEM Elements 360 application provide an additional layer of intelligence that prevents dangerous and unpleasant surprises when strong winds or sudden storms approach an area where hoisting and lifting are being done.

How to start a new future-ready crane safety program

If you’re a lift director, operations manager, safety supervisor, or any other leader working with crane operators, AEM is here to help you strengthen worker safety, align your operations with the weather to maximize productivity, and demonstrate compliance to regulators. We have experience helping businesses in shipping, transportation, construction, mining, and beyond improve their organizational approach to weather in ways that protect workers and reputations while providing better business intelligence.

Looking to master weather safety and crane operations? Let’s schedule a conversation!