ISO 23810:2019 Crane Safety Management Requirements
ISO 23810:2019 — Cranes — Safety Management Systems — Requirements is the system-level standard for crane safety management. It defines the framework requirements for the safety management system that user units must establish, covering safety policy, organizational responsibilities, risk control, training and assessment, inspection and maintenance, and emergency management.
Safety Management System Framework
ISO 23810:2019 structures the safety management system around the PDCA cycle (Plan-Do-Check-Act). The framework comprises the following elements: a safety policy statement in which the user unit sets out its commitment to crane safety and its overall objectives; organizational structure and responsibilities that clearly define the safety accountabilities of the designated safety leader, the safety management department, operators, and maintenance personnel; risk identification and control, which involves identifying, assessing, and implementing control measures for the operational risks of each crane; training and competency management to ensure all relevant personnel possess the required safety knowledge and operational skills; inspection and maintenance management to establish and execute a systematic inspection and maintenance regime; and emergency management, which requires developing emergency response plans for crane-related incidents and conducting regular drills.
The standard requires user units to maintain a comprehensive safety management documentation system, including: a compilation of safety management system documents and procedures; an equipment file for each crane (factory documentation, installation acceptance records, and all historical inspection reports); personnel files for operation and maintenance staff (training and assessment records, and validity of operator certificates); and records of incidents and abnormal events. The safety management system must undergo internal audits at least once a year, and management reviews by top management every two years, to drive continuous improvement in safety performance.
Risk Control Measures
Risk identification involves identifying hazards at every stage of crane operations — mechanical hazards, electrical hazards, falls from height, struck-by loads, overturning risks, and others — and assigning a risk level to each category based on severity × likelihood, graded from I to IV. Risk control follows a hierarchy of controls: hazard elimination (e.g., replacing equipment with safer alternatives), engineering controls (e.g., installing protective devices and safety interlocks), administrative controls (e.g., establishing Safety Operating Procedures and permit-to-work systems), and personal protective equipment (hard hats, Safety Belts, protective footwear, and other PPE).
Risk control for specific operating conditions — multiple cranes working in the same area (requiring an anti-collision plan and communication procedures), adverse weather operations (operating limits and stop conditions for wind speed, temperature, rain, and snow), and special Hoisting operations (dedicated plans and approval procedures for heavy lifts, precision lifts, and hazardous material lifts). The standard also mandates a permit-to-work system for critical lifting operations, requiring safety management personnel to assess risks and issue a work permit before operations commence.
| Safety Elements | requirements | Executing Personnel | Verification Method |
|---|---|---|---|
| Safety Policy | Development and Communication | Top Management | Document Review |
| Risk Identification | Comprehensive Identification Assessment | Safety Department | Risk Register |
| Training Management | Initial+Periodicrefresher training | Personnel/Technical | Assessment Records |
| Inspection System | daily inspection/monthly inspection/Annual Inspection | Operation/maintenance | inspection records |
| Emergency Management | Plan+Drill | Safety Department | Drill Report |
| Improvement Mechanism | Internal Audit+Management Review | Management Level | Audit Report |
Training and Competency Management
User units must establish a structured training system. Operator training follows ISO 23813 and includes at least 120 hours of combined theoretical and practical instruction, with a minimum pass rate of 80% on assessments. Maintenance personnel receive training in safety awareness, inspection methods, fault diagnosis, and repair techniques. Management training covers safety regulations and standards, risk management, and emergency response. Training plans should be reviewed and updated regularly to account for staff turnover and changes to applicable standards.
Competency management requires operators to hold a valid operating certificate, renewed through refresher training every two years. Maintenance personnel (including dedicated inspectors) must possess a lifting appliance safety management or inspection qualification. The standard also requires user units to maintain personnel records—including basic information, training history, assessment results, and certificate copies for each individual. Kelude offers safety management system development and training services in accordance with ISO 23810:2019.
Emergency Preparedness and Response
The standard sets clear requirements for emergency management. Emergency response plans must address potential crane-related incidents such as overturning, rope breakage, falling loads, and personnel injury, with defined response procedures and mitigation actions. Emergency facilities include first-aid kits, fire extinguishers, communication equipment, and emergency lighting. At least one emergency drill for crane operation incidents must be conducted annually, followed by an evaluation and improvement review. In the event of an incident, the emergency plan must be activated immediately and the incident reported to the relevant supervisory authority. Investigations follow the "four no-miss" principle: no closure until the cause is fully identified, responsible parties are held accountable, rectification measures are implemented, and all affected personnel have received appropriate education.
| Emergency Elements | requirements | Executing Personnel | Cycle |
|---|---|---|---|
| Emergency Response Plan | Preparation+Approval | Safety Department | At Establishment |
| Emergency Facilities | Equipment Complete and Functional | maintenance personnel | Quarterly Inspection |
| Emergency Drill | Including Hands-on Drill | Safety Department | Annually |
| Accident Report | 24hInternal Reporting | Safety Department | Upon Occurrence |
| Accident Investigation | Four-Not-Pass Principle | Management Level | Post-Accident |
FAQ
Q: What is the core framework of ISO 23810:2019?
A: It is built on the PDCA cycle (Plan-Do-Check-Act) and establishes a safety management system with six key elements: safety policy, organizational responsibilities, risk control, training management, inspection and maintenance, and emergency management. Internal audits are conducted annually, with a management review every two years.
Q: What is the hierarchy of risk control measures?
A: The hierarchy prioritizes hazard elimination, followed by engineering controls (guards/interlocks), administrative controls (procedures/permits), and personal protective equipment (hard hats, safety belts, safety shoes). Higher-level controls should be implemented wherever possible to reduce reliance on human behavior.
Q: What are the training requirements for operators?
A: Per ISO 23813, operators must complete at least 120 hours of combined theoretical and practical training and pass the assessment with a score of 80% or higher. Operator certificates require refresher training and re-certification every two years. Maintenance personnel must hold safety management or inspection qualification certificates. Personnel records must include training and assessment documentation.
Q: What does the emergency response plan cover?
A: The plan addresses incidents such as overturning, rope breakage, falling loads, and personnel injuries. First-aid kits, fire extinguishers, and other emergency equipment must be available on site. Drills are conducted annually. Accidents are investigated following the "four not to let go" principle. Kelude can provide consulting services to help users establish their safety management systems.
