Aerial lifts are powerful tools for working at height, offering efficiency and safety when used correctly. However, mistakes during operation can lead to accidents, equipment damage, and lost time. In this guide, we’ll explore the most common aerial lift mistakes and provide actionable tips to avoid them, ensuring safe, effective operations.
The most common accidents when operating aerial lifts are:
- Electrocutions: Electrocutions can happen when workers accidentally touch overhead power lines or when a lift comes into contact with them. Telescopic booms are particularly prone to electrical accidents since they frequently service electrical systems. Scissor lift operators, who often find themselves working near or beneath power lines, face numerous dangers of potentially fatal electrical shocks.
- Falls: According to the U.S. Centers for Disease Control and Prevention (CDC), falls from aerial lifts rank among the top causes of fatalities for construction workers. These dangerous incidents often happen when a worker, aerial lift, or scissor lift is struck by a crane, vehicle, or other objects.
- Aerial Lift tip-overs: Aerial lift tip-overs frequently happen when the load is too heavy, which reduces the vehicle’s stability. Tip-overs can also occur if the vehicle is set up on a slope that is more than 5 degrees (assuming that the vehicle is not equipped with the SlopeMax System from Versalift).
- Getting caught between a lift and an object: Injuries happen when an operator gets trapped between the moving bucket’s edge and a roof joist, beam, or other object.
- Being struck by objects outside the bucket: Accidents happen when operators aren’t fully aware of their surroundings, leading to unexpected encounters with materials that suddenly come loose and collapse.
However, accidents from aerial lifts can also have a lethal outcome. According to an elCOSH study, an average of 26 construction workers die each year in the US from using aerial lifts. In the study, boom lifts accounted for nearly 70 % of aerial deaths, and scissor lifts accounted for approximately 25 % of the deaths. Of course, not all aerial mistakes lead to deaths, but to minimize the unlikely and tragic event, it is necessary to know the mistakes that potentially can have a lethal outcome – and how to avoid them.
1. Neglecting Proper Training
First of all, operating an aerial lift requires more than just basic knowledge — it demands specialized training to understand the equipment’s capabilities, limitations, and safety features. Per ANSI A92.2, all operators are required to go through an operator training course on each individual unit they will be operating. A certificate of completion will be awarded to all that pass the course.
However, that does not authorize the operators to operate the unit.
In order to actually operate the unit, each operator must demonstrate to a qualified inspector that he/she can operate the unit safely and take it through its full range of motion. An “Authorization to Operate” document is required before an operator can use the aerial unit. This document must be signed by the Qualified Inspector.
Unfortunately, many organizations overlook this step, allowing untrained personnel to operate lifts.
The Consequences
Untrained operators may misuse controls, fail to recognize hazards, or handle emergencies improperly, possibly leading to accidents, injury, and equipment damage. Lack of training also reduces efficiency, as operators spend more time troubleshooting or correcting errors.
How to Avoid It:
- Ensure all operators undergo certified training programs specific to the lift type they’ll be using and that they have been approved to operate the unit by a qualified inspector.
- Provide hands-on practice under supervision to build confidence and competence.
- Schedule annual refresher courses to keep operators updated on the latest safety practices and regulations.
2. Overloading the Lift
Each aerial lift has a defined weight limit designed to ensure safe operation. Unfortunately, operators often underestimate the combined weight of tools, materials, and personnel, which can lead to the unit tipping over.
The Consequences
Overloading can cause equipment instability, structural damage, and tipping, putting everyone on-site at risk. It also accelerates wear and tear, shortening the equipment’s lifespan.
How to Avoid It
- Always check the lift’s load capacity before use, considering the weight of tools, materials, and operators.
- Use load scales or calculate weight accurately to ensure compliance.
- If the job demands a higher capacity, choose a lift designed for heavier loads rather than risking overload.
3. Ignoring Ground Conditions
Aerial lifts require stable and even ground to maintain balance during operation. Operators who skip site assessments risk working on uneven terrain, loose gravel, or slopes, all of which can compromise safety.
The Consequences
Unstable ground increases the likelihood of tipping, slipping, or the lift becoming stuck. These hazards not only delay the project but also put operators at risk of serious injury.
How to Avoid It
- Conduct a thorough pre-operation site inspection to identify any potential ground issues.
- Use stabilizers or outriggers to balance the lift on uneven surfaces.
- Invest in ground mats or portable platforms to provide additional stability on soft or loose terrain.
- Avoid operating lifts in areas with visible hazards, such as sinkholes or erosion.
4. Failing to Perform Pre-Operation Inspections
Aerial lifts are complex machines with numerous components that must function correctly. Skipping pre-operation inspections can lead to overlooked issues, such as hydraulic leaks, worn-out parts, or malfunctioning controls.
The Consequences
Uninspected equipment is more likely to fail during operation, leading to accidents, project delays, and costly repairs. Neglecting inspections also increases liability in the event of an accident.
How to Avoid It
- Follow the Pre-Start Inspection Checklist in the Operator Manual as well as the Service Manual.
- Always relieve the hydraulic pressure before working on any hydraulics. The hydraulic oil is under high pressure and leaks can cause a high pressure spray that can cause serious burns or get in the eyes.
Pay special attention to hydraulics, brakes, controls, safety systems, and tires. - Train operators to recognize early signs of wear or damage and report them immediately.
- Schedule regular maintenance with certified technicians to address underlying issues. The Service Manual outlines prescribed service intervals as well as a detailed list of what needs to be serviced at each interval.
5. Operating in Unsafe Weather Conditions
Weather is a critical factor in aerial lift operations. High winds, heavy rain, and low visibility can compromise stability and reduce operator awareness, yet many projects proceed without considering these risks.
The Consequences
Unsafe weather increases the risk of equipment tipping, operator injury, and accidents caused by impaired visibility. Wind, in particular, can destabilize elevated platforms, making it hazardous to work at height. Never operate a unit then there are wind gusts of over 25 mph.
How to Avoid It:
- Check weather forecasts and wind speeds before beginning any operation.
- Follow manufacturer guidelines regarding maximum allowable wind speeds.
- Postpone operations during heavy rain, snow, or high winds to ensure safety.
- Provide operators with weather-resistant clothing and equipment to maintain visibility and control in mild conditions.
6. Misusing Safety Equipment
Personal protective equipment (PPE) is a vital line of defense for aerial lift operators, yet improper use or neglect is a common mistake. Harnesses left unfastened or helmets not worn correctly can turn minor mishaps into major injuries.
The Consequences
Neglecting PPE increases the severity of accidents, particularly falls or head injuries. Misused equipment may also fail during an emergency, leaving operators vulnerable. If there is a reportable accident, OSHA can fine the utility for not taking appropriate measures to ensure the operator was using the proper PPE.
How to Avoid It:
- Require operators to wear full-body harnesses, helmets, and fall protection systems at all times.
- Train staff on the correct use, adjustment, and maintenance of PPE.
- Conduct regular PPE inspections to ensure compliance with safety standards.
- Replace damaged or outdated equipment immediately to maintain reliability.
7. Poor Communication on Site
Effective communication is essential for safe aerial lift operation, especially on busy job sites with multiple teams. Misunderstandings between operators and ground staff can lead to collisions, inefficiencies, or even injuries.
The Consequences
A lack of communication increases the likelihood of accidents, delays workflows, and creates confusion about responsibilities.
How to Avoid It
- Establish clear communication protocols, such as standard hand signals or radio communication.
- Assign a spotter or supervisor to coordinate activities and guide operators in congested areas.
- Conduct daily safety briefings to ensure all team members understand the plan and their roles.
- Use visual aids, such as cones or signs, to mark operational zones and prevent unauthorized access.
Avoiding these common aerial lift mistakes is essential for safe, efficient operations. From proper training and routine inspections to understanding site conditions and weather, proactive measures save time, reduce risks, and protect your team.
Read more about aerial lift safety here: Safety Guidelines for Aerial Lift Use: Protecting Your Crew [LINK to blog post, when it has been approved and posted on the website).
Partner with Versalift for reliable aerial lifts and expert safety resources. Our equipment is designed to meet the highest safety standards, ensuring your team works securely and efficiently at height. Contact us today to learn more about our solutions.