How to ensure the safety of operators during routine and extraordinary maintenance operations on crane runway beams and overhead cranes?

In Italy, Legislative Decree no. 81 of 2008, known as the “Consolidated Law on Occupational Safety”, aims to establish uniform protection standards for workers across the country.
This applies to all sectors, including maintenance and access operations for overhead cranes and their runway beams in industrial facilities.

Runway beams represent a serious fall hazard for operators who need to intervene on malfunctioning cranes or even just pass along them. For this reason, adequate measures must be implemented to prevent and protect against falls from height, in accordance with current regulations.

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Pillar structure analysis: A technician must perform a thorough assessment of the pillars supporting the runway to determine the most suitable system and verify that the structure can withstand loads in case of a fall.

Design: A preliminary design must be drafted to evaluate the actual ergonomics of the lifeline and perform necessary assessments and corrections. If it is not possible to completely prevent fall scenarios, the clearance distance should be calculated. This parameter defines the minimum space required to prevent the operator from hitting the floor or other obstacles in case of a fall.

Accessibility: Verify safe access to the runway, either via a rope ladder or aerial work platform (AWP) suitable for boarding.

Surface inspection: To ensure operator safety, check not only the risk of falling outside the runway but also the presence of unprotected skylights, smoke vents, shafts, or any other hazards.

During a site inspection at a large facility, one often notices overhead crane traffic.

For safety professionals, the obvious question arises: what if a malfunction occurs at such height? How can operators work safely?

Different scenarios arise depending on the type of malfunction and maintenance.
Some situations can be resolved by positioning an AWP and performing work directly from the basket. However, this is not always possible because it depends on where the crane stopped and whether there are obstacles for the AWP.

So how do we reach the area?

Simple, we use the crane runways as described above. Once we reach the area where the crane has stopped, the operator can transfer onto it, detach from the runway lifelines, attach to the lifelines installed directly on the crane (usually parallel to the walkway or at the trolley), and complete the work.

Access methods using lifelines are defined by strict regulations and safety procedures to ensure maximum worker protection. A correct approach relies on detailed planning and the use of appropriate equipment. It is essential to plan from the outset safe access to the structure, not only for system installation but also for future maintenance. This ensures that every intervention can be carried out safely and in full compliance with regulations.

• Access points must be secure and clearly indicated in the Technical File, often equipped with a tag showing the fall protection system data and the last inspection date.
• Workers must use PPE in compliance with regulations, such as harnesses, lanyards, connectors, and energy absorbers. These devices must be inspected periodically and worn correctly.
• Once at the access point, the operator attaches to the lifeline before proceeding. They must remain connected to the system at all times while traversing or staying on the runway, following the specified paths and instructions.
• All workers accessing the runway must receive specific training and practical instruction on the correct use of fall protection systems and associated PPE.