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Lockout/Tagout: Preventing Hazardous Energy Risks in Crane & Rigging Operations

Safety on the Job |

In crane and rigging operations, controlling hazardous energy is critical to worker safety. Whether servicing a crane, repairing a hoist, or maintaining rigging equipment, unexpected energy release can cause severe injuries or equipment damage. Lockout/​Tagout (LOTO) procedures prevent this by ensuring machinery is properly shut down and cannot restart until maintenance is complete. Without LOTO, workers are at risk of electrocution, crushing injuries, or being caught in moving machinery.

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Hazardous energy comes in many forms, and understanding these risks and controlling them is key to preventing accidents. Electrical energy from overhead crane circuits, hydraulic power controlling booms and outriggers, and pressurized air in pneumatic tools all pose serious hazards. Mechanical energy from winches, hoists, and rigging components can be dangerous if they move unexpectedly. A proper LOTO procedure ensures that all these energy sources are safely controlled before maintenance begins.

How Lockout/​Tagout Works in Crane & Rigging Operations

LOTO is more than just placing a lock on a switch. It is a structured process that ensures equipment cannot be activated while work is in progress. The main steps include:

  • Identifying Energy Sources: Recognizing all energy inputs, including electrical, hydraulic, and pneumatic systems.
  • Shutting Down Equipment: Powering down cranes, hoists, and rigging machinery before work starts.
  • Isolating Energy Sources: Disconnecting or blocking energy inputs to prevent accidental activation.
  • Applying Locks and Tags: Physically locking out controls and attaching warning tags to indicate that the equipment is being serviced.
  • Releasing Stored Energy: Safely discharging any remaining energy in the system, such as residual hydraulic pressure.
  • Verifying Isolation: Checking that the equipment is completely de-energized before starting maintenance.

Each of these steps must be followed without shortcuts. If even one is skipped, workers are at risk of serious injury.

Who Is Responsible for LOTO?

LOTO requires teamwork. It involves several roles within a crane and rigging operation.

Hoist Technicians
  • Authorized Employees: These workers are trained to apply and remove locks and tags. They are responsible for isolating equipment and ensuring it cannot be restarted.
  • Affected Employees: These are workers who operate or work near equipment undergoing maintenance. They must be aware of LOTO procedures and never attempt to remove locks or restart machinery.
  • Other Employees: Even those not directly involved in maintenance must understand LOTO procedures. Accidental interference can cause serious harm.

Clear communication is essential. All team members should know when LOTO is in effect and what it means for their work.

Common Mistakes That Lead to Accidents

Despite strict procedures, LOTO failures still happen. The most common mistake is skipping steps in the process. Workers may assume a machine is off and safe to work on without fully isolating energy sources. In other cases, stored energy isn’t properly released, leading to sudden movements or pressure releases.

Another frequent issue is poor communication. If an operator isn’t aware that maintenance is happening, they may try to restart a crane or hoist, putting workers at risk. Training helps prevent these errors, but consistent reinforcement is necessary.

The Bigger Picture: Why LOTO Matters in the Crane Industry

Controlling hazardous energy through Lockout/​Tagout is more than just a safety protocol — it’s a life-saving practice. In the crane and rigging industry, where heavy machinery operates under extreme conditions, one mistake can mean the difference between a routine maintenance check and a catastrophic accident. LOTO ensures compliance with OSHA regulations, prevents costly downtime, and protects workers from life-threatening hazards.

Safety is not just about rules and procedures. It’s about making sure every worker goes home unharmed. Controlling hazardous energy by taking the Lockout/​Tagout process seriously is a responsibility that benefits everyone on the job site. By following proper energy control practices, the crane industry can operate safely, efficiently, and confidently.