Overhead crane operations are critical in various industries, from manufacturing to construction, requiring precision and safety. Yet, despite stringent guidelines and safety protocols, certain dangerous practices persist—side pulls being one of the most problematic. Side pulls occur when the load is lifted or moved horizontally rather than vertically. Even though this method is still in use in some settings, it places immense stress on cranes and hoists, significantly increasing the risk of equipment failure and injury. Side pulls should never be used, no matter the situation, and safer alternatives for material handling must be prioritized.
The Hidden Risks of Side Pulls
At first glance, side pulls may appear as a convenient solution to reposition loads without realigning the crane. However, this maneuver presents dangers that aren’t always apparent until late. Side pulls introduce horizontal forces into a crane system that handles vertical forces. These additional forces strain the equipment, potentially causing malfunctions that could lead to crane collapse or other accidents.
The most concerning aspect of side pulls is how easily they can be misjudged. A load that is only slightly off-center may seem insignificant to the operator. However, a minor deviation from vertical alignment—just a few degrees—places extra tension on the crane cables and pulleys. This stress increases the likelihood of wear and tear or total equipment failure. The Occupational Safety and Health Administration (OSHA) defines side pulls as “pulls acting horizontally when the hoist lines are not operated vertically” (OSHA 29 CFR 1910.179). This indicates that side pulls are recognized as a significant risk to equipment and safety.
Side pulls continue to be used in some crane operations mainly due to convenience, lack of operator training, and misunderstandings about the risks involved. Crane safety regulations have existed for decades, with the first standards prohibiting side pulls appearing as early as the 1970s. For instance, OSHA adopted crane safety guidelines from the American National Standards Institute (ANSI) B30.2 and B30.5 as early as 1967, which explicitly prohibited side pulls due to their hazardous nature.
Despite these longstanding prohibitions, side pulls still account for numerous yearly crane-related injuries and fatalities. This ongoing issue is compounded by operators who may not fully appreciate the dangers or incorrectly assume that minor side pulls won’t affect the crane’s stability.
Why Side Pulls Cause Equipment Failure
The main danger of side pulls is that cranes are engineered to lift vertically. When a crane hoists a load from a directly overhead position, the weight is distributed evenly across its components, including the cables, pulleys, and crane structure. This allows the equipment to function within its designed capacity. However, the forces become unbalanced when a load is moved horizontally during a side pull. The crane is suddenly subjected to diagonal forces it wasn’t built to handle.
The effects of this imbalance can be severe. For example, side pulls may cause the load to swing unpredictably, generating a pendulum effect that adds even more stress to the crane. The result is often increased wear on cables, sheaves, and pulleys. In extreme cases, side pulls can cause the crane to collapse entirely, leading to potentially fatal accidents and substantial damage to nearby property.
Real-world data backs up these risks. According to industry reports, side pulls contribute to around 175 injuries and 45 fatalities annually in the U.S. alone. These incidents aren’t just rare exceptions but a consistent problem affecting even well-maintained equipment.
Common Accidents Caused by Side Pulls
It helps to examine real-world incidents to better understand the dangers of side pulls. In one case, a crane operator at a scrap yard attempted a side pull to lift a heavy load. The crane’s boom collapsed, causing a fatal accident that might have been prevented with proper hoisting techniques. Investigators later found damage to the crane’s sheave, a clear indicator that the equipment had been exposed to repeated side pulls over time.
In another incident, high winds worsened the effects of a side pull during the installation of a transformer. As the load swung unpredictably, it damaged the surrounding area, endangering workers’ lives and resulting in costly repairs. While side pulls might seem practical in tight spaces, their real-world consequences often far outweigh any perceived benefits.
Eliminate Side Pulls for Good
While side pulls may still be performed in certain operations, they remain a hazardous and outdated practice. The risks associated with side pulls—ranging from equipment damage to fatalities—are too significant to justify their continued use. Instead, operators should focus on proper crane alignment and take advantage of safer, more efficient alternatives like portable gantry cranes or LMIs.
At SISSCO Hoists, we believe in upholding the highest safety standards. We strictly adhere to OSHA and Crane Manufacturers Association of America (CMAA) guidelines, designed to ensure the safe and efficient use of cranes. These guidelines, which explicitly prohibit side pulls due to their hazardous nature, are based on extensive research and industry best practices. By avoiding side pulls and following these proper hoisting practices, we can protect our workers, preserve our equipment, and guarantee smooth operations for all our material handling projects.
