Crane critical lifts represent the highest-consequence lifting operations in construction. When a 100-ton pick goes wrong, people die and equipment costing millions gets destroyed. The written lift plan is what stands between a successful lift and a fatal incident.
When Is A Lift Critical?
OSHA 1926 Subpart CC doesn't use the exact term "critical lift," but ASME B30.5 and industry practice trigger critical lift status when:
- Load exceeds 75% of crane capacity at working radius
- Multi-crane pick (tandem lift)
- Personnel platform hoisted by crane
- Load near or over energized lines
- Load over occupied buildings or public roads
- Blind pick (signal person or operator can't see load)
- Precision placement (anchor bolts, coupling alignment)
- Adverse weather
- Owner or GC designation
What The Plan Must Include
- Project and pick identification
- Load information — description, weight (verified), dimensions, center of gravity, pick points
- Crane information — make, model, operator certification, boom length, counterweight, capacity at radius
- Rigging plan — sling type, size, capacity, inspection date, hardware, capacity calculation
- Ground conditions — bearing pressure, mat plan, outrigger position
- Environmental limits — wind speed abort criteria
- Communication — signal person qualification, radio channel, hand signals, chain of command
- Exclusion zone — swing radius, barricades, personnel access control
- Personnel roster with roles
- Emergency plan
- Abort criteria and stop-work authority
- Approvals — lift director, operator, signal person, safety rep
What's In The Forbes Crane Lift Pack
- Standard critical lift plan — mobile crane
- Tandem lift plan (dual crane coordination)
- Personnel platform lift plan (man basket)
- Blind pick plan (with camera/signal relay)
- Pick and carry lift plan
- Ground bearing pressure calculation worksheet
- Sling capacity calculation worksheet
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Frequently Asked Questions
Who has to sign a critical lift plan?
At minimum: lift director (person in charge), crane operator, signal person, and project safety representative. On owner/GC projects, add their safety rep. For personnel hoisting, every person on the platform signs. Signatures should be dated and collected BEFORE the pick, not after.
At what percentage of crane capacity does a lift become critical?
Industry standard is 75%. Some owners and contractors use 80% or 85%. Below 75%, standard lift procedures apply. At or above 75%, treat as critical and require a written plan. Above 90%, most owners require secondary crane on standby.
Does every pick need its own plan?
For truly critical lifts, yes — each pick has different load, radius, ground conditions, and personnel. For repetitive picks (tower stacking), a master plan with per-pick attachments documenting the variables is acceptable. Never use a single 'blanket' plan for varied picks.
What's the difference between gross and net crane capacity?
Gross capacity = what the crane can lift structurally and for stability. Net capacity = what you can hang after subtracting rigging, hook block, jib, auxiliary equipment. Load charts show gross. You must calculate net for the actual pick. Missing this is how cranes tip over.
Do I need a critical lift plan for a helicopter external load?
Yes. Helicopter external load work is critical under FAA 14 CFR Part 133 and OSHA. Plan needs pilot qualification, aircraft ID, load carousel or sling configuration, ground team qualification, fuel plan, wind window, communication protocol, landing zone identification, and emergency jettison protocol.
What are typical wind abort criteria for crane picks?
Manufacturers publish wind speed limits — usually 20-30 mph for boom operation, less for pick-and-carry. Wind turbine work typically aborts at 9 m/s hub height (20 mph). Bridge and building picks often use 25-30 mph. Get the actual manufacturer spec for your crane and your load.