Crane Safe Use & Operator Certification Requirements

Published in 2010, GB/T 25849-2010 "Cranes — Safe Use — Part 1: General Principles" serves as the master standard for the safe use of all crane types. It covers the full spectrum of crane categories — including Bridge Cranes, Gantry Cranes, Tower Cranes, Mobile Cranes, and Railway Cranes — providing user units with a complete framework and detailed guidelines for establishing a safety management system. Kelude Heavy Industry applies this standard when developing Operation Manuals for its clients and delivering operator safety training.

Establishing a Comprehensive Safety Management System

The standard requires user units to establish a robust safety management system that encompasses, at a minimum, operating procedures, daily inspection protocols, a Maintenance program, and an emergency plan for accident response. Operating procedures must clearly define the standard operating sequence for each crane type, prohibited actions, and emergency response methods. The inspection system should specify the items, frequencies, and record templates for both Daily Inspections and Periodic Inspections. The Maintenance system must outline the intervals, scope, and Acceptance Standard for each level of servicing. The emergency plan should cover emergency response and rescue measures for common accident scenarios, including crane-related injuries, falls from height, electric shock, and Overturning.

Each crane must have a technical documentation file that records the complete lifecycle history — from manufacturing and Installation Acceptance through Periodic Inspection, Maintenance and Retrofit work, and any incident handling. This documentation serves as the cornerstone of full life cycle management and provides the essential basis for accident Traceability and hazard analysis. The file should include the Factory Certificate, material certificates for primary load-bearing structural components, installation self-inspection records, supervision inspection reports, all periodic inspection reports, Maintenance logs, and incident records. User units must designate a responsible person to manage the technical documentation, ensuring its completeness, continuity, and Traceability.

The standard further mandates clear allocation of safety responsibilities. The head of the user unit bears primary accountability for crane safety and must establish a safety management structure with dedicated or part-time safety personnel. These safety managers are responsible for developing operating procedures and inspection systems, supervising operators' day-to-day practices, conducting regular safety inspections and safety training, and managing the rehearsal and revision of the emergency plan. A full-scale emergency response drill must be conducted at least once a year to validate the plan's practicality and the personnel's response capability.

Operator and Signal Person Qualification Requirements

Operators must complete professional training and pass the assessment to obtain a special equipment operator certificate before being permitted to work. Operators who have been away from the job for more than six months must be re-assessed. Operators are expected to have thorough knowledge of their crane's performance parameters, Operation Mode, safety device functions, and emergency response procedures, and must complete no fewer than 24 hours of continuing safety education annually. Signal persons must wear a clearly visible identification badge and direct operations using standard hand signals or two-way radio communication. Signals must be clear, unambiguous, and easily understood. Operators have the right to refuse to act on an unclear signal and must immediately confirm the intended meaning with the signal person.

Both signal persons and operators must undergo regular health examinations to confirm they remain fit for their duties. The standard specifies that individuals with conditions that could compromise safe operation — including hypertension, heart disease, epilepsy, vertigo, color blindness, and hearing impairment — are not permitted to work as crane operators or signal persons. Operators must assess their own physical condition before starting work and must not operate a crane if feeling unwell or fatigued. Operation under the influence of alcohol or medications affecting the nervous system is strictly prohibited. Reliable two-way communication must be established between the signal person and the operator; in situations where visibility is obstructed or noise levels are high, radio communication devices must be used.

In terms of personnel management, user units must maintain a dynamic register of operators and signal persons, recording certificate numbers, validity periods, training assessment results, health examination records, and any disciplinary actions for violations. Certificate renewal applications must be submitted three months before the expiry date. The register must be updated promptly when personnel transfer or leave, ensuring that all active personnel hold valid, compliant certificates. User units must not assign uncertified personnel to operate or direct cranes; violations are subject to legal liability.

Safe Operating Procedures and Prohibited Practices

Before commencing operations, a Daily Inspection must be performed to confirm that the Brake, Limit Switch, Wire Rope, Lifting spreader, and all safety devices are in proper working condition. A Trial Lift is required prior to the actual lift: the load should be raised approximately 200 mm off the ground to verify brake reliability and load stability. The hoisting and traversing mechanisms must never be operated simultaneously. During operation, the operator must remain fully attentive, continuously monitoring both the load and the surrounding area, and must stop immediately if any abnormality is detected. Upon completion of work, the Hook should be raised to its upper limit position, the main Power Supply switched off, and the Control Grip or Remote Control secured properly.

The standard explicitly prohibits the following practices: Overloading — operations must stay within the Rated Lifting Capacity, including the combined weight of the Hook block and Lifting spreader; angled lifting — the sling must be vertical relative to the load's center of gravity, as angled pulls create horizontal force components that can cause Overload; lifting loads of unknown weight — buried or frozen loads must never be lifted; using Limit Switches as a normal stopping method — Limit Switches are safety protection devices and must not replace standard operating controls; and passing loads over personnel — the load path must avoid areas where people are present. These prohibitions represent the safety baseline distilled from years of field experience, and violations of these rules are the direct cause of the vast majority of crane accidents.

The standard also stipulates that operators must remain at their operating position throughout the lifting process and must not leave the controls unattended. No one is permitted to stand beneath a suspended load, and the area below the load must be cordoned off with warning barriers. Night operations require adequate illumination of the work area, with illuminance of no less than 50 lx. Crane operations must be halted during severe weather conditions such as high winds, heavy rain, or dense fog. When multiple cranes operate in the same area, a dedicated coordination plan must be developed to prevent collisions or interference. During shift handover, the outgoing operator must fully brief the incoming operator on the equipment's working condition and any relevant precautions; the incoming operator must perform a Pre-Shift Inspection, and both parties must sign off before the handover is complete.

Shift Handover and Multi-Crane Coordination

The standard specifies shift handover procedures. The outgoing operator must raise the hook to its upper limit, disconnect the main power supply, and clear the operating area before handover. The handover report must cover equipment operating conditions during the shift, any abnormalities encountered, corrective actions taken, and safety precautions for the incoming shift. The incoming operator should arrive 10–15 minutes early, review the operation log, perform a pre-shift inspection, and only assume control once the equipment is confirmed to be in proper condition. Both operators must sign the operation log to acknowledge the handover. Operation must not proceed if the handover is incomplete; if necessary, the equipment supervisor should be called in to mediate.

When multiple cranes operate on the same rail or within the same work area, the user unit must develop a coordination plan. This plan should define each crane's working radius, travel routes, and right-of-way rules. A minimum safety distance of 1 m must be maintained between adjacent cranes, and when traveling in the same direction, a following distance of at least 2 m is required. Cross operations involving multiple cranes require a dedicated person to direct unified command, and all operators must maintain clear communication. For multiple tower cranes, the working radius coverage must be calculated to prevent interference between jibs or suspended loads. Where necessary, end stops or zone-limiting devices should be installed.

Crane Safe Use Management System Comparison Table

The comparison table below summarizes the key content and implementation requirements of four types of safety management systems: operating procedures, inspection systems, maintenance systems, and emergency plans. User units can use this framework to establish and improve their own safety management systems item by item.

Crane Safety FAQ: Common Questions & Best Practices