Overhead Crane Rigging Training Program Breakdown

Comprehensive Safety & Certification Training – 3P Safety

I. Introduction to Overhead Crane Rigging

Objective: Introduce participants to the role of a rigger in overhead crane operations and the importance of safety in lifting tasks.

• Overview of Overhead Crane Operations

  • Definition and purpose of overhead cranes in material handling

  • Common applications: assembly lines, steel fabrication, shipping/receiving

• Role of the Rigger

  • Responsibilities for attaching and detaching loads

  • Ensuring safe load path and communication with crane operators

• Importance of Rigging Safety

  • OSHA accident statistics and case studies

  • Potential hazards: pinch points, dropped loads, swinging loads

  • Safety culture and accountability

II. OSHA & Industry Regulations

Objective: Familiarize trainees with legal and regulatory requirements for rigging and crane operations.

• OSHA Standards

  • OSHA 1910.179 – Overhead and Gantry Cranes

  • OSHA 1910.184 – Slings

  • OSHA 1926 Subpart CC – Cranes and Derricks in Construction (if applicable)

• ASME and ANSI Standards

  • ASME B30.2 – Overhead and Gantry Cranes

  • ASME B30.9 – Slings

  • ASME B30.26 – Rigging Hardware

• Employer Responsibilities

  • Daily inspections and maintenance

  • Operator and rigger qualification requirements

• Employee Rights and Responsibilities

  • Stop-work authority

  • Reporting unsafe conditions

III. Crane Components and Rigging Equipment

Objective: Understand the components of overhead cranes and rigging gear to ensure safe operation.

Overhead Crane Components

• Bridge, trolley, hoist, hook block

• Runway rails and end trucks

• Electrical systems and pendant controls

Rigging Equipment Identification

• Slings:

  • Wire rope slings, chain slings, synthetic web/slings, and round slings

• Rigging Hardware:

  • Shackles, hooks, eye bolts, turnbuckles, spreader bars, and lifting beams

• Load Handling Attachments:

  • Magnets, grabs, clamps, and vacuum lifters

• Inspection Points:

  • Wear, distortion, broken wires, cracks, and load rating verification

IV. Load Charts, Weight Calculations & Center of Gravity

Objective: Teach participants how to calculate load weight, determine center of gravity, and select proper rigging.

• Load Weight Determination

  • Reading tags, drawings, and manufacturer specifications

  • Using formulas for volume and material density

• Center of Gravity (COG) Principles

  • Identifying COG to prevent tipping or shifting loads

• Load Charts and Rated Capacities

  • Understanding Safe Working Load (SWL) and Working Load Limit (WLL)

  • Effects of sling angles on load capacity

• Angle Factor Calculations

  • Sling tension formulas

  • Multi-leg sling configurations and derating

V. Rigging Inspection and Pre-Lift Checks

Objective: Instill best practices for pre-operation inspections to prevent failures.

• Daily Inspection Requirements

  • Crane controls, hooks, wire ropes, and safety devices

• Rigging Gear Inspection

  • ASME B30.9 guidelines for slings and hardware

• Tagging Out Defective Equipment

  • Marking and removing damaged rigging from service

• Pre-Lift Checklist

  • Load path clearance

  • Communication plan with crane operator

  • Verifying weight and rigging selection

VI. Rigging and Lifting Techniques

Objective: Provide hands-on knowledge for proper lifting, rigging, and load handling.

• Rigging Best Practices

  • Proper sling angles and hitch types (vertical, basket, choker)

  • Securing unstable or irregular loads

  • Balancing loads using spreader bars and equalizers

• Safe Lifting Techniques

  • Smooth hoisting and lowering to prevent shock loading

  • Keeping personnel clear of the load path

• Load Movement

  • Controlling swing, rotation, and travel

  • Avoiding sudden starts/stops and side pulling

VII. Communication and Signal Person Training

Objective: Teach proper communication protocols between riggers and crane operators.

• Standard Hand Signals

  • ANSI B30.3 and OSHA standard signals

  • Directional and emergency stop signals

• Radio Communication

  • Clear phrasing and repetition techniques

• Signal Person Responsibilities

  • Maintaining line of sight

  • Acting as the operator’s “eyes and ears”

VIII. Emergency Procedures

Objective: Prepare trainees to respond to emergencies safely.

• Power Failure and Mechanical Failures

  • Lowering or securing loads in the event of a malfunction

• Load Drop or Sling Failure

  • Site evacuation procedures and reporting protocols

• Weather-Related Hazards

  • Wind, rain, and temperature impacts on lifting operations

• Lockout/Tagout (LOTO) Protocols

  • Securing equipment for maintenance or inspection

IX. Maintenance and Recordkeeping

Objective: Ensure compliance with maintenance and inspection requirements.

• Routine Maintenance

  • Lubrication, wire rope inspection, and electrical checks

• Rigging Gear Storage

  • Proper storage to prevent corrosion and mechanical damage

• Documentation

  • Daily inspection logs

  • Monthly and annual inspection records

  • Rigger and operator training certifications

X. Hands-On Practical Training

Objective: Apply classroom knowledge to real-world scenarios.

• Conducting equipment inspections

• Performing proper rigging of loads

• Executing safe lifts under supervision

• Demonstrating signal communication

XI. Final Evaluation & Certification

• Written Exam

  • 50–100 questions covering OSHA regulations, rigging, and crane safety

• Practical Skills Test

  • Demonstration of proper rigging, signaling, and safe lift execution

• Certification

  • Awarded to participants who meet performance and knowledge standards

Training Duration Recommendation

• Total Program: 1- Days (Depending on experience level)