LFT/Specific Lifts/TBT-LFT-042

Safe Use of Overhead Gantry Crane

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Safe Use of Overhead Gantry Crane

Toolbox Talk Record

Ref: TBT-LFT-042  |  Issue: 1  |  Date: April 2026
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What?

  • An overhead gantry crane runs on rails fixed to building columns or supports above the working area.
  • They are commonly found in pump houses, process buildings, workshops, and plant rooms on construction sites.
  • LOLER 1998 requires overhead cranes to undergo thorough examination every 12 months by a competent person.
  • Only trained and authorised operators may use overhead gantry cranes on site.
  • The safe working load (SWL) is displayed on the crane and must never be exceeded.
  • Pendant controls, radio controls, or cab controls are used depending on the crane configuration.
  • Overhead crane accidents commonly involve dropped loads, collisions, and crushing of ground workers.
  • The travel path of the crane must be clear of obstructions and personnel before operation begins.
  • End stops, limit switches, and overload protection devices are critical safety features that must function.
  • Pre-use checks must cover the hook, wire rope, limit switches, controls, and rail track condition.

Why?

Prevent dropped loadsA load falling from an overhead crane can kill instantly even from a low height due to its mass.
Crush injuriesWorkers can be crushed between the crane bridge, load, or building columns if the path is not clear.
Legal complianceLOLER 1998 requires lift plans, thorough examinations, and competent operators for all crane lifts.
Do Don't
  • Complete a pre-use check of the hook, rope, controls, and limits each shift.
  • Confirm the load weight before lifting and verify it is within the SWL.
  • Ensure the travel path is clear of people, obstructions, and overhead hazards.
  • Use the correct slings and lifting accessories rated for the load.
  • Keep the load as low as practicable during travel to reduce swing risk.
  • Sound the warning horn before moving the crane in any direction.
  • Check that thorough examination certificates are current and on site.
  • Use tag lines to control and position the load during movement.
  • Park the crane with the hook raised and controls secured when not in use.
  • Report any unusual noises, jerky movements, or control faults immediately.
  • DON'T exceed the safe working load displayed on the crane at any time.
  • DON'T stand or walk under a suspended load or within the travel path.
  • DON'T operate the crane if any limit switch or overload device is bypassed.
  • DON'T use the crane to drag loads sideways — it is for vertical lifting only.
  • DON'T leave a load suspended when stepping away from the controls.
  • DON'T operate if the wire rope shows broken wires, kinking, or corrosion.
  • DON'T use the crane for personnel lifting without an approved arrangement.
  • DON'T allow untrained personnel to operate pendant or radio controls.
  • DON'T travel the crane at speed — approach end stops and loads slowly.
  • DON'T wrap slings around the hook — use the correct hook latch method.

See also: Lifting Operations Awareness (LOLER) | Chain Slings and Shackles Inspection
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