By James Headley, Founder & CEO of Crane Institute of America (CIA) and Crane Institute Certification (CIC)
Rail-mounted overhead cranes are a backbone of many factories, mills, and industrial plants. While these cranes are often operated from the floor using wired or wireless remotes, certain situations demand an extra layer of safety and precision—enter the signalperson.
When a Signalperson Is Needed
In most scenarios, crane operators can move freely to see the load, its travel path, and potential obstacles. However, there are times when the operator is in a cab high above the floor, or when the lift involves moving behind structures or machinery that block visibility.
In these cases, a trained signalperson is indispensable. Their role is more than just support—they direct the entire crane operation, ensuring safety and efficiency from start to finish.
The Signalperson’s Critical Role
Although the crane operator controls the machinery, the signalperson dictates how and where the crane moves, and at what speed. OSHA underscores the importance of this by requiring operators to follow signalperson instructions unless the directions are unclear.
Essentially, the signalperson is running the crane by proxy.
Training and Qualifications: Meeting OSHA Standards
Signalpersons often handle other jobs like rigging, but when they signal, they must be fully qualified. To meet OSHA’s requirements, they need to:
- Master the basic hand and voice signals used with overhead cranes.
- Understand crane mechanics, limitations, and the physics of lifting, moving, and stopping loads.
- Identify hazards such as obstacles, machinery, and live power conductors.
- Ensure that no part of the crane or load endangers workers.
Employers are responsible for confirming that a signalperson meets these standards.
How to Become Qualified
There are multiple paths to training:
- Attend professional courses (like those offered in-person or online by the Crane Institute of America).
- Learn directly from an in-house expert or safety specialist.
- Train under the mentorship of an experienced signalperson.
Experience shows that blending classroom instruction with hands-on practice is the most effective approach.
Once trained, candidates must pass an assessment conducted by a competent evaluator. OSHA requires employers to keep records of this qualification before the signalperson can legally direct crane operations.
Communication: The Lifeline of Safe Lifting
Clear, constant communication between the signalperson and the operator is non-negotiable. Signals may be visual, verbal, or a combination of both, and must be agreed upon before lifting begins.
Special crane attachments or operations might call for custom signals, but these must never conflict with standard ones. Directions should always be given from the operator’s perspective (e.g., “trolley right” means move the trolley to the operator’s right).
Verbal Signal Checklist
Every verbal instruction should include, in order:
- Function and direction
- Distance and/or speed
- Function stop
For example:
“Travel north 25 ft – 15 ft – 10 ft – 5 ft – 2 ft – travel stop.”
Required Best Practices on the Job
When a signalperson is active on a lift, they must:
- Stay positioned where they can clearly see the operator, the load, and its destination.
- Keep unnecessary personnel out of the work area.
- Never direct loads over people.
- Halt operations immediately if communication is disrupted.
- Use standard ASME B30.2, B30.16, and B30.17 hand signals, unless approved voice communication is used.
An employer can send them to a professional trainer like Crane Institute of America, whose courses are available both in person and now online.
An employer can have a knowledgeable person from its organisation – for example, a safety specialist – teach the aspiring signaller. The employer can even assign one of its experienced signallers to mentor the novice.
In any case, experience has proven that a combination of classroom and hands-on training is most effective.
Once trained, aspiring signallers must be assessed as qualified by a competent assessor designated by their employer. The assessment can include oral and written questions about crane operation and safety, as well as questions about any plant-specific procedures and, of course, demonstration of the standard hand signals used with overhead cranes.
It’s important to note that OSHA requires the employer to keep a record of the assessment. Only then can a new signalperson legally begin giving signals to a crane operator.
Clear Communication Is Vital
Constant communication with the crane operator must be maintained during the operation of moving loads.
Safe and successful crane operation depends on clear, accurate communication between the signaller and the crane operator. The signals between the two may be visual, verbal, or a mix of the two.
Before beginning a lifting operation, the operator and signaller must identify each other and confirm the signals to be used and how they will be delivered.
Special signals may be used for cranes with separately operated hoists, special operations or crane attachments not covered by standard hand or voice signals.
If special signals are needed, they must not conflict with standard signals, and the signalperson and crane operator must agree on them in advance.
Directions given to the crane operator must be presented from the crane operator’s perspective. For example, “trolley right” must mean move the trolley to the operator’s right.
Verbal instructions must contain these elements in this order:
- Function and direction
- Distance and/or speed
- Function stop
Also, verbal directions must be continuous. For example:
“Travel north 25 ft – 15 ft – 10 ft – 5 ft – 2 ft – travel stop.”
Before a signalperson gives the crane operator directions to do multiple functions at the same time—for example, trolleying and load lowering—the signaller should consider the lift’s complexity, the crane’s capability, the operator’s skill, and the ability to communicate the needed voice signals.
Required Procedures
When a signalperson is involved in a lift, he or she must:
- Be positioned where he or she can clearly see the crane operator, the travel path and where the load will be placed.
- Keep non-essential people out of the work area.
- Never direct the load over people.
- Not give directions that would move a load if the travel path isn’t clear.
- Communicate continuously with the operator. If communication is disrupted, equipment movement must be stopped until communication is restored.
- Give signals that the operator can see or hear and understand. If the operator cannot understand a signal, he or she must not respond.
- Use the standard hand signals prescribed in applicable ASME B30.2, B30.16 and B30.17 standards, unless voice-communication equipment is used.
For more information, visit www.craneinstitute.com.
Much of the information in this article can be found in Headley’s book Overhead Cranes, which can be purchased at the same website.
A signalperson must thoroughly understand the hand/voice signals used with overhead cranes.
About the Author
James Headley is the founder and CEO of Crane Institute of America (CIA) and Crane Institute Certification (CIC).
The CIA trains operators, riggers, supervisors and others who use all types of cranes and equipment. The CIC tests those professionals to industry and governmental standards. Headley’s extensive expertise in cranes and rigging comes from more than 40 years in the industry.