Visualizing safety: operator aids that perform

Running a crane has become almost as complicated as piloting a huge passenger jet. Operating systems feature a host of technologies that give the operator critical information about the jobsite, the load and the crew.

What used to be considered “bells, buzzers and whistles,” these systems have become critical operator aids that help ensure safer lifting operations. Crane cameras, video feeds, communications equipment and anti-collision devices assure that the crane operator has a full “view” of the load and the surrounding jobsite.

ACT rounded up an array of these products, with a focus on visibility and communications in the crane cab and on the jobsite.

Wireless crew communication

E-Pak full duplex radios combined with Lazer Pro headsets from the Eartec Company are a new concept in crane communications. The Eartec system utilizes sleek, lightweight headsets with Bluetooth connectivity eliminating wires along and bone conduction technology so that messages are received by vibration through the skin.

The Eartec system is sleek and lightweight and yet features a very powerful connectivity system that allows for hands-free communication.

These wireless intercoms are a breakthrough because they provide simultaneous talk, hands-free communication leaving ears uncovered so that crews can monitor the surrounding environment including the sound of machinery engines, according to the company. E-PAK transceivers weigh only 2.5 ounces and are tucked inside a pocket or clipped to clothing.

Hard hat compatible Lazer Pro headsets include a discreet back band and two bone conducting disks that sit comfortably on the temple leaving ears uncovered. A totally portable E-Pak wireless intercom will link up to nine users within a 400-yard range enhancing coordination, productivity and safety.

Integrated dash camera

Telematics adoption in the lifting industry has been far outpaced by other segments in the construction market. To date, many crane owners haven’t seen a value proposition in outfitting their fleets for GPS and component tracking, but as insurance premiums continue to sky-rocket, dual-facing dash cameras are making their way onto large and small fleets alike.

At several past SC&RA events, insurance company representatives and progressive crane owners are singing the praises of this technology for mitigating risks and proving their drivers weren’t at fault, in most cases, during accident disputes. These devices are now standard equipment on most over-the-road trucking fleets when hauling heavy equipment and are now commonly found on-highway trucks and all-terrain cranes along with the fleet’s trucks that support them.

A1A Software’s dual facing dashcam that reports to company’s iCraneTrax portal.

Some self-insured crane groups are now mandated to install the dual-facing cameras by their carriers. In the current litigious environment, dash cameras provide owners with a safety net to monitor the driving habits of their operators, both good and bad, that can be used in training. Perhaps most importantly, dash cameras capture video with triggers on aggressive driving and, of course, can capture the “truth” in a near-miss or accident.

A few crane owners are using dash cameras on jobsites to document all the activity associated with lift including ground personnel, signal persons, other equipment and riggers.

Most dash-camera portals are stand-alone for specific devices and don’t integrate with a company’s fleet management or business system. There are software providers that integrate dash camera reporting, traditional telematics information and fleet management activity.

Bottom line, it may be time for the lifting industry to raise the bar and utilize the technology available.

Harsh environment visibility

The CAM 61 from AMCS Technologies is a professional camera system developed to enhance visibility, safety and precision during lifting operations on cranes. Designed specifically for demanding construction sites, the CAM 61 improves operator awareness by delivering high-quality live video directly to the cabin.

Equipped with a high-definition sensor, 36x optical zoom, 16x digital zoom and infrared night vision (ICR filter), the system provides a detailed view of the hook and load, even in low-light or long-distance conditions. The integrated autofocus and image stabilization features ensure clear footage, even during crane movement or under vibration.

AMCS’s CAM 61 was designed to operate in harsh environments.

A key advantage of the CAM 61 is its autonomous power system with an extended runtime of up to 44 hours. This allows for long operating periods without requiring a fixed power source, making installation and relocation quick and flexible.

The system includes a 12-inch HD touchscreen monitor with an intuitive user interface. A video recording (MP4 format) is also available, enabling review of operations and enhancing site traceability when enabled.

Built for harsh environments, the CAM 61 is housed in a durable casing designed for outdoor use, with reinforced materials to withstand dust, moisture and site conditions.

Trusted on major projects across the world, CAM 61 reflects AMCS Technologies’ decades-long expertise in lifting safety. The company’s deep understanding of field requirements, combined with high-quality manufacturing and dedicated customer support, makes the CAM 61 a reliable and effective operator-assist solution.

Enhancing load visibility

In lifting environments, operator awareness and load visibility are critical, not just for safety, but for operational efficiency. The Magnetek Intelli-Lift System from Columbus McKinnon is designed to enhance both by detecting misalignments and snags in real time, giving operators the information they need to safely and accurately manage each lift.

The Magnetek Intelli-Lift has the ability to track and log misalignment events.

The Intelli-Lift System acts as a highly responsive operator aid, alerting users in real time to load misalignments, side pulls or snags. These situations, often invisible from the cab or control station, can lead to swaying loads, equipment damage or worker injury if not corrected quickly. With Intelli-Lift, directional lights and an optional warning horn provide clear, instant feedback. Operators can respond manually or utilize the optional auto-correction mode, which re-centers the hoist above the load before lifting continues. By ensuring proper alignment, the system minimizes strain on equipment and improves lifting accuracy.

What sets Intelli-Lift apart is its ability to track and log misalignment events. This data enables better decision-making, whether it’s optimizing equipment layout or reinforcing training protocols. Access to this data is wireless and intuitive, compatible with mobile and desktop devices for quick, on-the-floor insights. The system is engineered for flexibility, allowing for easy integration into new or existing applications. Its robust construction is suitable for both indoor and outdoor use, even in harsh environments. By actively detecting and responding to misalignment scenarios, Intelli-Lift supports greater awareness of both the load and surrounding jobsite conditions, making it a critical safety tool for operators in high-demand lifting environments.

Multi-zone radar sensing

As radar and safety systems have almost become an industry standard in the automotive industry, mobile machinery is following the same course. However, the systems must be even more sophisticated to account for different types of heavy equipment. Simpler systems that have a standard alarm for all objects don’t work for machines with booms or tools extending outward or within busy job sites where people work in close proximity to the machine.

GS Global Resources integrates programmable multi-zone safety systems designed specifically for OEMs in the mobile machinery sector. These systems integrate high-speed 79 GHz radar sensors with Convoy camera technology, delivering significantly faster response times and superior detection compared to traditional 24 GHz systems. Each radar sensor provides three segment zones, further divided into five subdivisions, enabling precise monitoring up to 40 meters from the machine and detecting objects as close as 10 inches.

GS Global Resources integrate programmable,multi-zone safety systems.

A key feature is the system’s customizable zoning, allowing OEMs to program dead zones or set different warning levels for each area. The integration with real-time camera feeds ensures operators have a comprehensive view of their surroundings, enhancing situational awareness. The system is embedded directly into the machine’s main control system, making it feel like a native feature rather than an add-on. OEMs can easily select configurations based on machine needs with additional options for automatic braking and tailored alarm systems. The robust, IP69K-rated sensors are suitable for both off-road and highway applications, ensuring durability in harsh environments.

This full integration not only improves operator experience but also demonstrates to end users that safety is a core part of the machine’s design, not an afterthought. The system’s flexibility and advanced capabilities make it an ideal solution for OEMs seeking to elevate safety standards in their equipment.

Video transmission

Operating cranes and heavy machinery often involve working in areas with limited visibility. In such situations, operators may need to navigate tight, confined spaces to visually inspect for obstacles, check container fill levels, or accurately position a crane hook. This not only disrupts workflow but can also pose safety risks.

HBC-radiomatic, Inc., a global leader in radio control systems for cranes and machinery, offers an innovative solution: the radiomatic photon. This advanced feature enables real-time video transmission directly to a 3.5-inch or 5-inch color display integrated into the radio control unit. Supporting up to four cameras, which can be flexibly mounted on the machine or within the work area, the system provides operators with a comprehensive view of their surroundings. Users can choose to view a single camera feed or monitor all four simultaneously via a split-screen display. The high-quality video is transmitted through a dedicated radio link, and operators can easily switch between video feeds and diagnostic data as needed.

With radiomatic photon, operators gain a clear, continuous view of the work zone, enabling them to respond to potential hazards in real time.

With radiomatic photon, operators gain a clear, continuous view of the work zone, enabling them to identify and respond to potential hazards in real time. This significantly enhances workplace safety. The system also supports precise maneuvering in complex or hard-to-reach areas, improving operational accuracy. Additionally, by reducing the need for physical inspections, it boosts efficiency, saving time, energy and effort during routine tasks. For low-light or night-time operations, infrared cameras can be integrated to ensure visibility at all times.

Preventing blind operations

On today’s fast-paced and ever-changing jobsite, blind operations carry more risks than ever. From team turnover to long hours and tight deadlines, modern work environments face life-threatening dangers under the wrong conditions. That’s where HoistCam comes in.

Hoist Cam’s mission is to give operators the visibility aids they need to have live visuals during what are all too often blind lifts/picks or evolutions. The result is not only a more productive workplace, but the peace of mind knowing your team has the equipment they need to avoid dangerous incidents.

HoistCam is an operator aid that has evolved and matured into a trusted technology serving the crane industry.

It’s a simple concept. A HoistCam placed on the block or the tip of a crane transmits a wireless video feed directly to an operator’s monitor. The operator then has a 1080P High Definition and real-time view into what is taking place when they normally would see little or nothing.

HoistCam is not only built to perform, but to be as easy as possible, the company said. Installation is fast and simple, taking 20 minutes on most equipment, and up to two hours on tower cranes. Instead of requiring modifications to equipment, the camera/transmitter is secured using rare earth magnets and a safety lanyard and can be powered using a battery or natively from the crane itself. The antenna, receiver and monitor are positioned at the cab, and powered natively from the equipment as well, reducing any potential downtime.

Beyond its signature camera devices, HoistCam has created a suite of accessories to enhance performance, from the spare battery pack that extends operations for up to 24 hours, to recording capabilities for training purposes and safety reviews.

Powerline safety

SIG-LITE is a Powerline Warning Device and risk management tool built on 50 years of proven reliability and dependability. Designed for rugged use in construction, mining, telecommunications and the aerial lift rental markets worldwide.

The SIG-LITE unit will automatically default itself to warn of close proximity to overhead distribution power lines.

Several new developments have been advancing the PWD market, including the EU Regulation (EU) 2023/1230 Risk of contact with live overhead power lines.

Depending on their height, mobile machinery or related products shall, where relevant, be designed, constructed and equipped, so as to prevent the risk of contact with an energized overhead power line or the risk of creating an electric arc between any part of the machinery or an operator driving the machinery and an energized overhead power line.

When the risk to the person’s operating machinery incurred by the contact with an energized overhead power line cannot be fully avoided, mobile machinery or related products shall be designed, constructed and equipped so as to prevent any electrical hazards.

Distribution power lines are generally classified between (7.2kV -13.5kV) and are estimated to account for over 96 percent of all overhead HV power lines in the USA. The SIG-LITE unit will automatically default itself to warn of close proximity to overhead distribution power lines. If work is required around higher voltage transmission lines simply switch to the alternate transmission setting pre-calibrated for these higher voltages.

Sigalarm is working with two of the largest fleet owners in the U.S.

Control of the load

The Vita Load Navigator 2.0 (VLN 2.0) provides crane operators and rigging teams with precise, hands-free control of suspended loads, regardless of wind, height or complexity of the jobsite.

Unlike traditional stabilization methods, the VLN is a semi-autonomous propulsion-driven device that connects below the hook of the crane, enabling crews to counteract load swing and spin remotely. Operators can adjust heading, pitch and roll in real time using a wireless controller from up to 600 feet away, keeping personnel clear of danger zones while maintaining full situational awareness.

The VLN 2.0 delivers load control and situational awareness.

Its smart feedback system delivers real-time orientation and battery data to operators, and its modular design sets it apart. High-powered fans can be reconfigured mid-project, mounted on different spreader bars or attached directly to the load. When C.S. McCrossan needed to shift from a 20-foot to a 15-foot spreader on a 40-ton lift at a jobsite this summer, they made the change in-house thanks to their Tier 1 Service Partner support package, which provided the necessary instructions.

Recently in Austin, Texas, VLN assisted crews at DPR Construction and Skyhook Ops in safely removing barrier panels from the 74-story Waterline tower, despite wind gusts reaching 40 mph. In San Francisco, Clark Pacific used the VLN during the erection of a 10-story parking structure. When high winds halted 49 subcontractors, their team kept working because the VLN kept each lift stable and on schedule.

Utilized across heavy construction, energy and infrastructure projects, the VLN is available in standard configurations like 40 T-7, 40T-11, 40T-15 and 40T-20 models, as well as custom configurations to accommodate unique projects. It integrates seamlessly into existing rigging setups and installs in minutes.n