Cranes and lifting equipment

Why lifting loads is a priority risk

Lifting loads concentrates potential energy and heavy masses above areas where people work. A sling failure, an unlatched hook, overloading, maneuvering in windy conditions, the overturning of a poorly stabilized mobile crane, or the boom coming into contact with a power line frequently cause serious and fatal accidents in construction, industry, logistics, and ports. Regulations address this risk from three angles: the design and marketing of equipment, its safe operation, and mandatory industrial safety inspections.

Royal Decree 1215/1997 establishes in its Annex I the minimum provisions for load lifting equipment (solidity and stability, indication of nominal load, devices against load falling and overload, signage) and in its Annex II the conditions of use: stability of the equipment, prohibition of passing loads over unprotected persons, visibility of the operator or signalman, lifting accessories selected according to the load and marked, prohibition of lifting persons except with equipment provided for this purpose or exceptional measures, and suspension of maneuvers with wind or other adverse weather conditions.

In the area of ​​industrial safety, the Regulation on Lifting and Handling Equipment establishes technical instructions for tower cranes (MIE-AEM-2, approved by Royal Decree 836/2003) and for self-propelled mobile cranes (MIE-AEM-4, approved by Royal Decree 837/2003), which regulate installation, periodic inspections by control bodies, maintenance by maintenance companies, and the licenses for crane operators and self-propelled mobile crane operators. Overhead cranes and hoists comply with the manufacturer’s specifications and applicable UNE-EN standards.

Usage requirements (Royal Decree 1215/1997)

• Stability and installation. Installation of demountable or mobile equipment in a way that guarantees stability, with stabilizers, supports and suitable terrain, and checks after assembly and periodically.
• Rated load and accessories. Rated load marked on the equipment, lifting accessories (slings, chains, hooks, eyebolts) selected according to the load, gripping points, the hooking device and atmospheric conditions, marked and stored in a way that prevents deterioration.
• Maneuvers. Prohibition of keeping suspended loads unattended and passing them over unprotected work areas occupied by people; signalmen or media when the operator cannot see the load; standardized signal protocol in accordance with Royal Decree 485/1997.
• Lifting of persons. Only with equipment and accessories provided for this purpose; exceptionally, with equipment not provided for, provided that the relevant measures are adopted and adequate supervision is present.
• Weather conditions. Suspension of outdoor use when conditions (wind, storm, ice) may affect safety, with anemometers and defined limits.
• Interference. Measures to avoid collisions between cranes whose operating radii overlap and safety distances to overhead power lines.
• Training and authorization. Specific training for operators, sling operators and signalmen, and express authorization from the company; regulatory licenses for tower cranes and self-propelled mobile cranes.

Inspections and maintenance

• Checks under Royal Decree 1215/1997. Initial check after installation, periodic checks and checks after exceptional events, by competent and registered personnel.
• Tower cranes (MIE-AEM-2). Installation project, assembly by authorized company, inspection by control body at commissioning and periodically, maintenance by conservation company, crane logbook and crane operator’s license.
• Self-propelled mobile cranes (MIE-AEM-4). Periodic inspections by an inspection body according to age, maintenance in accordance with the manufacturer, documented annual inspection and operator’s license.
• Lifting accessories. Visual inspection before each use, periodic inspections by a competent person, removal of damaged slings and chains, and recording of accessories.
• Overhead cranes and hoists. Maintenance and inspections in accordance with the manufacturer and applicable UNE-EN standards, with special attention to brakes, limit switches, load limiters, cables and hooks.

Organizational application: how to manage lifting equipment

1. Inventory the lifting equipment and accessories with their rated loads, manufacturer documentation, regulatory inspections and responsible parties.
2. Plan each significant lifting maneuver: load weight and dimensions, appropriate equipment and accessories, exclusion zone, signal person, weather conditions and nearby power lines.
3. To train and authorize operators, slingmen and signalmen, and to verify the regulatory cards of crane operators and mobile crane operators.
4. Establish the program of checks and maintenance in accordance with Royal Decree 1215/1997 and the applicable ITC, with contracts with control bodies and conservation companies.
5. Implement the inspection of lifting accessories before each use and their periodic review, with removal of damaged ones.
6. Define the procedure for lifting people, limited to planned equipment or exceptional cases with documented measures.
7. Investigate incidents (load drops, overloads, activation of limiters) and review procedures.

Preventive management software allows you to maintain the inventory of lifting equipment and accessories with their regulatory inspections, operator authorizations and licenses, maneuver plans and incidents, with expiration notices.

Limits and common mistakes

1. Exceeding the rated load or lifting loads with unsuitable or damaged accessories.
2. Passing suspended loads over people or leaving them suspended unattended.
3. Operating without a signalman when the operator cannot see the load, or with non-standardized signals.
4. Lifting people with unforeseen equipment and without documented exceptional measures.
5. Continue maneuvers in wind or other adverse conditions, or without considering nearby power lines.
6. Omitting mandatory inspections of tower cranes and mobile cranes or maintenance by a maintenance company.

The technical requirements are detailed in Royal Decree 1215/1997, in the ITC of the Regulation of lifting equipment and in the applicable UNE-EN standards; this sheet is for informational purposes.

Regulatory and reference framework

• Royal Decree 1215/1997, of July 18, Annexes I and II . Minimum provisions and conditions for the use of work equipment for lifting loads.
• Royal Decree 836/2003, of June 27. Supplementary technical instruction MIE-AEM-2 on tower cranes for construction or other applications.
• Royal Decree 837/2003, of June 27. Supplementary technical instruction MIE-AEM-4 on self-propelled mobile cranes.
• Royal Decree 1644/2008, of October 10. Rules for the marketing and commissioning of machinery, including lifting equipment.
• Royal Decree 485/1997, of April 14. Safety and health signage , including hand signals for maneuvers.
• Technical guide for the assessment and prevention of risks related to the use of work equipment (INSST) . Criteria for the application of Royal Decree 1215/1997 to lifting equipment.

The UNE-EN 13001 (cranes, design), UNE-EN 13155 (lifting accessories) and UNE-EN 14439 (tower cranes) standards are acquired through the Spanish Association for Standardization; the autonomous communities manage the crane operator and mobile crane operator licenses.