Risk assessment is the cornerstone of safe crane operations on construction sites. Whether it involves a tower crane, mobile crane, or derrick, lifting operations inherently involve hazards that must be identified, evaluated, and mitigated before work begins. In Hong Kong, the requirement to perform a site-specific risk assessment is mandated under the Factories and Industrial Undertakings (Lifting Appliances and Lifting Gear) Regulations (FIU LALG) and emphasized in both the Code of Practice for Safe Use of Tower Cranes and the CIC Guidelines on Safety of Tower Cranes. Conducting an effective risk assessment not only ensures compliance with statutory obligations—it also significantly reduces the chance of accidents, operational delays, and legal liabilities.
A proper crane-related risk assessment must begin during the planning stage of the lifting operation. It is not a generic formality but a tailored process that considers the unique characteristics of the site, load, crane type, and environmental conditions. The assessment must be led by a competent person, defined as someone with relevant training, experience, and authority to evaluate the risks and recommend appropriate control measures. This person is typically the lifting supervisor, site engineer, or safety officer responsible for the lifting operation.
The first step in an effective crane risk assessment is hazard identification. This includes examining the physical conditions of the site—such as overhead obstructions, ground stability, underground services, and adjacent structures—as well as operational factors like load weight, load shape, lifting height, swing radius, and nearby traffic. Other common hazards include poor visibility, high wind speeds, power lines, and simultaneous activities nearby. The Code of Practice emphasizes that tower crane operations involve complex movement across multiple axes and that uncontrolled loads, mechanical failure, or poor communication can result in serious accidents if risks are not thoroughly identified and addressed.
Once hazards have been identified, the next step is risk evaluation. This involves analyzing the likelihood of each hazard materializing and the potential consequences if it does. Risks should be categorized as low, medium, or high, and prioritized accordingly. For instance, lifting a heavy load over a public road presents a high risk due to the potential for injury and public disruption, whereas hoisting light materials within a fenced exclusion zone may present a lower risk. The evaluation should also consider cumulative risks, such as lifting in poor weather combined with long load radii, which may independently be moderate but together present a high hazard profile.
After evaluation, the risk assessment must propose control measures to eliminate or reduce the identified risks. These may include engineering controls such as limit switches, load moment indicators (LMIs), anemometers, and anti-collision systems. Administrative controls such as exclusion zones, lift permits, method statements, weather monitoring, and lifting schedules are also key tools. The CIC Guidelines recommend that complex lifts, such as tandem crane lifts or night-time operations, include a “hold point” mechanism, where operations pause for verification before proceeding. Personal protective equipment (PPE) like harnesses, helmets, and high-visibility clothing should also be part of the control strategy, but must be seen as the final line of defense—not the primary safeguard.
Effective communication is essential for implementing the risk assessment. The findings and recommended control measures must be shared with all parties involved in the lifting operation, including the crane operator, slinger, signaler, and ground crew. A pre-lift briefing should be conducted to explain the scope of work, assigned roles, identified hazards, and response procedures in the event of an emergency. The Code of Practice highlights that communication breakdown is a leading cause of crane incidents, particularly when workers are unaware of surrounding risks or assume others have taken precautions on their behalf.
Crane-specific risk assessments must also consider environmental factors. Wind speed, temperature, rain, and lighting conditions can all affect crane stability and lifting accuracy. For example, tower cranes are particularly sensitive to wind due to their height and long jib structure. Operations should cease when wind speeds exceed manufacturer recommendations, generally around 9 m/s for standard operations. Wind monitoring should be continuous, and emergency procedures must be established to secure the crane in weathervaning mode or safe park position if environmental conditions deteriorate rapidly.
All risk assessments must be documented, signed by the competent person, and retained on-site for reference and audit purposes. This documentation should include the date of assessment, scope of lifting operation, list of identified risks, proposed control measures, and the names of those involved in the planning process. For critical lifts or operations involving public interfaces, the risk assessment should also be reviewed and approved by the principal contractor or project manager. The FIU LALG regulations make clear that failure to conduct a risk assessment is not only a procedural lapse—it is a prosecutable offence.
Risk assessments are not static documents. They must be reviewed and updated whenever site conditions change, such as crane relocation, changes in crane configuration, new structural elements on site, or updated load requirements. A new risk assessment is also required after any incident or near miss to prevent recurrence and ensure lessons learned are incorporated into future planning. Site managers should establish a review cycle to periodically validate the relevance of each assessment and confirm that all control measures remain in place and effective.
In summary, conducting an effective risk assessment for crane work is both a regulatory requirement and a practical necessity. It forms the backbone of safe crane operation, guiding the planning, control, and supervision of all lifting activities. By following the framework established in the FIU LALG, and supported by the Code of Practice for Safe Use of Tower Cranes and the CIC Guidelines, contractors and safety personnel can build a robust safety culture that proactively manages risk, protects workers, and ensures operational excellence.
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