1. PURPOSE
This Standard Operating Procedure establishes the minimum requirements for the safe pre-use inspection, operation, and post-use shutdown of the overhead cranes and vacuum lifters at Rossen Glass & Mirror Ltd. The two overhead cranes cover the majority of the shop floor and are the primary means of lifting and positioning glass and mirror. Correct use of this equipment protects employees from serious crush and laceration injuries, prevents product damage, and ensures the equipment remains in safe working order.
2. SCOPE
This SOP applies to all trained shop floor employees who operate either of the two overhead cranes and their associated vacuum lifters at the Rossen Glass & Mirror Ltd. facility. It covers all crane-assisted lifts of glass, mirror, and related materials at any stage of fabrication. Manual handling of glass is governed separately by SOP SHP-GLS-001 — Glass & Mirror Handling.
3. RESPONSIBILITIES
Crane Operator
- Complete this SOP training before operating either crane independently.
- Perform a full pre-use inspection of the crane and vacuum lifter before every lifting session.
- Never exceed the rated lifting capacity of the crane or vacuum lifter.
- Take the crane out of service immediately if any fault or abnormal behaviour is observed, and report it to a supervisor.
- Ensure the area under and around the load is clear before and during every lift.
Supervisor
- Ensure all crane operators are trained and have reviewed this SOP before operating independently.
- Maintain the crane inspection log and arrange scheduled maintenance and certification.
- Investigate all crane-related incidents, near-misses, and vacuum failures.
- Ensure rated load capacities are clearly posted on each crane and vacuum lifter.
4. EQUIPMENT OVERVIEW
Rossen Glass & Mirror Ltd. operates two overhead bridge cranes, each fitted with a vacuum lifter. Together they cover the majority of the shop floor. Key details operators must know before use:
| Item | Crane 1 | Crane 2 |
|---|
| Location / coverage zone | Refer to shop floor plan posted at crane controls | Refer to shop floor plan posted at crane controls |
| Rated lift capacity | Posted on crane — check before every lift | Posted on crane — check before every lift |
| Vacuum lifter rated capacity | Posted on lifter unit — check before every lift | Posted on lifter unit — check before every lift |
| Controls | Pendant or remote — refer to manufacturer label | Pendant or remote — refer to manufacturer label |
| Emergency stop | Red mushroom button on pendant / control panel | Red mushroom button on pendant / control panel |
NOTE: Never assume the rated capacity from memory. Always read the posted capacity label on the crane and on the vacuum lifter before beginning a lift.
5. HAZARDS & RISK SUMMARY
| Hazard | Potential Harm | Controls |
|---|
| Vacuum seal failure mid-lift | Glass dropping from height — severe laceration, crush injury or fatality | Pre-use cup inspection; gauge monitoring throughout lift; never stand under load |
| Overloading the crane or lifter | Structural failure, dropped load | Always verify weight against posted rated capacity before lifting |
| Load swinging or spinning | Collision with personnel or equipment | Low travel speed; use tag line or gloved hand to guide; no sudden movements |
| Contaminated suction cups | Reduced grip — seal failure, dropped load | Clean cups and glass surface before every lift; inspect cup condition |
| Pinch points — load vs. rack or table | Crush injury to hands or feet | Keep hands clear during lowering; steel-toed footwear mandatory |
| Crane travel into obstruction | Equipment damage; load destabilisation | Clear travel path before moving; operate at low speed |
| Lifting cracked or damaged glass | Glass breaking under vacuum load — dropped load, laceration | Inspect glass for damage before attaching lifter; do not lift compromised pieces |
| Wet or contaminated glass surface | Cup seal failure | Wipe glass surface dry and clean before attaching lifter |
| Bystanders in the lift zone | Struck by swinging or dropped load | Call "Glass in the air"; clear the zone before and during every lift |
6. REQUIRED PERSONAL PROTECTIVE EQUIPMENT (PPE)
| PPE Item | When Required | Mandatory? |
|---|
| Steel-toed footwear | At all times on the shop floor | YES |
| Safety glasses | Whenever glass is being lifted or positioned | Highly Recommended |
| Hard hat | Whenever working under or near a suspended load | Highly Recommended |
| Cut-resistant gloves (ANSI A4) | When guiding glass by hand during crane positioning | YES — when hand-guiding |
7. PRE-USE INSPECTION
A pre-use inspection must be completed before the first lift of every working day, or before any lift following a period of inactivity. Do NOT use a crane or vacuum lifter that fails any check — take it out of service, tag it, and notify your supervisor.
7.1 Overhead Crane
1
Visual inspection of bridge and trolleyWalk the crane coverage area and visually inspect the bridge beam, trolley, and hoist unit for visible cracks, deformation, loose bolts, or missing components. Do not operate if any structural damage is found.
2
Check the hoist cable or chainInspect the hoist cable or chain for kinks, fraying, broken strands, corrosion, or wear. Any of these findings is an immediate out-of-service condition.
3
Check the hook and safety latchConfirm the hook is not cracked, bent, or twisted. The safety latch must spring back and seat fully. A hook with a missing or non-functioning latch must not be used.
4
Test the controls — no loadPower on the crane and test all pendant or remote control functions with no load: hoist up, hoist down, travel left, travel right, bridge forward, bridge back. All movements must respond correctly and stop promptly when the control is released.
5
Test the emergency stopWith the crane powered and in motion, press the emergency stop button. The crane must stop immediately. Reset and confirm normal operation before proceeding.
6
Check limit switchesJog the hoist slowly upward and confirm the upper limit switch stops travel before the hook block reaches the hoist drum. Do not bypass or defeat limit switches.
7
Confirm rated capacity label is legibleThe crane's rated load capacity must be clearly posted and readable from the operating position. If the label is missing or illegible, do not use the crane until it is replaced.
7.2 Vacuum Lifter
1
Inspect the suction cupsExamine every suction cup for cracks, tears, cuts, hardening, or distortion. A damaged cup cannot form a reliable seal — replace it before use. Do not use a lifter with even one damaged cup.
2
Check cup seating surfacesConfirm the lip of every cup is clean, pliable, and free of glass dust, grit, oil, or debris. Clean with a damp cloth if needed. Contaminated cups will not seal correctly.
3
Inspect the vacuum gaugeThe vacuum gauge must be intact, readable, and the needle must rest at zero when the lifter is not engaged. A cracked gauge face or a needle that does not return to zero is an out-of-service condition.
4
Inspect hoses and fittingsCheck all vacuum hoses for cracks, kinks, or loose fittings. Any air leak in the vacuum circuit will reduce holding force — hoses must be in sound condition before use.
5
Test the vacuum pump and seal — no glassActivate the vacuum pump. The system should build to operating pressure quickly. Place a gloved palm over one cup and confirm suction is felt. Release and confirm the gauge drops back toward zero when the vacuum is released.
6
Test the release mechanismConfirm the manual vacuum release handle or valve operates freely and releases suction smoothly. A stiff or stuck release is an out-of-service condition.
7
Confirm rated capacity label is legibleThe vacuum lifter's rated capacity must be clearly posted on the unit. If missing or illegible, do not use until replaced.
8. OPERATING PROCEDURE
8.1 Before Every Lift
1
Estimate the load weightBefore attaching the lifter, estimate the weight of the glass piece (thickness × area × 2.5 kg/m² per mm of thickness). Confirm the estimated weight is within both the crane's and the vacuum lifter's rated capacity. If unsure, ask a supervisor — never guess.
2
Inspect the glass surface and conditionCheck the glass for cracks, chips, or damage before lifting. A compromised piece may fracture under vacuum load. Do not lift cracked or severely damaged glass with the vacuum lifter — consult a supervisor for an alternative method.
3
Clean and dry the lift area on the glassWipe the area of the glass where the cups will attach. Remove all water, glass dust, oil, and debris. The surface must be clean, dry, and flat for all cups to seal.
4
Clear the lift zoneBefore attaching the lifter, call out "Glass in the air" to alert others. Confirm no employee, bystander, or obstruction is beneath the intended lift path or landing zone. The area must remain clear for the entire duration of the lift.
5
Position the lifter centrally on the glassLower the vacuum lifter so all cups contact the glass simultaneously. The lifter must be centred on the piece so the load hangs balanced when lifted. An off-centre attachment can cause the glass to tilt and the seal to fail on one side.
6
Engage the vacuum and confirm the sealActivate the vacuum pump. Watch the gauge rise to the operating range — the manufacturer's safe zone marked on the gauge face. Confirm every cup is sealed by checking that the gauge holds steady. If the gauge drops or will not reach the safe zone, disengage, reposition, and retry. Do not lift if the gauge will not hold.
8.2 Performing the Lift
1
Test lift — raise only a few centimetresRaise the load just 5–10 cm off the surface and stop. Pause for several seconds and watch the gauge — it must remain in the safe zone. Confirm the glass is hanging level and balanced. If the gauge drops, lower immediately, release vacuum, and investigate before retrying.
2
Raise to the minimum safe travel heightOnce the test lift is confirmed safe, raise the load only as high as needed to clear obstacles in the travel path. Keep the load as low as safely possible throughout travel — a lower load is more stable and less dangerous if a fault occurs.
3
Move slowly and deliberatelyTravel the crane at the lowest practical speed. Avoid sudden starts, stops, or direction changes — these cause the load to swing and put stress on the vacuum seal. Smooth, controlled movement is always required.
4
Monitor the gauge continuously during travelKeep an eye on the vacuum gauge throughout the lift. If the gauge drops below the safe zone at any point during travel, stop the crane immediately and lower the load to the nearest safe surface as quickly and smoothly as possible.
5
Guide with a gloved hand or tag line — never your bodyIf the glass needs to be rotated or steered into a precise position, use a gloved hand placed flat on the glass surface, or a tag line. Never use your body, another person, or any part of a machine to stop a swinging load.
6
No one under the load at any timeNo employee may stand directly under or immediately beside a suspended glass load at any point during the lift — not to guide it, not to check the landing zone, not for any reason. Maintain the cleared zone until the glass is fully set down and the vacuum released.
8.3 Setting Down the Load
1
Confirm the landing zone is readyBefore lowering, confirm the table, rack, or machine is correctly set up, clear of obstructions, and ready to receive the glass. Do not lower onto a surface that is not prepared — hover and wait if needed.
2
Lower slowly and keep hands clearLower the glass slowly and steadily. Keep all hands and feet clear of the pinch zone between the glass and the receiving surface. Use a tag line or guide stick rather than bare hands to control position at the last moment.
3
Confirm the glass is fully supported before releasingThe glass must be resting fully and stably on the landing surface before the vacuum is released. Never release the vacuum while the load is still partially in the air or balanced on an edge.
4
Release the vacuumOperate the release handle or valve to disengage the vacuum. Confirm the gauge drops to zero and all cups release cleanly. Do not pull the lifter away by force if any cup remains attached — release fully first.
5
Raise the lifter clearOnce all cups have released, raise the lifter clear of the glass before moving the crane. Do not drag the lifter sideways across the glass surface.
⚠ WARNING: NEVER stand under a suspended glass load — not for any reason, at any stage of the lift. A vacuum seal can fail without warning. If the gauge drops during a lift, lower immediately, call out "Glass coming down", and clear the area.
9. POST-USE PROCEDURE
1
Park the craneReturn the crane to its designated parked position at the end of each use or shift. Lower the vacuum lifter to a safe, stable resting height — not dangling freely at full extension.
2
Power downSwitch off the crane controls and vacuum pump. If the crane has a master power isolator, engage it at the end of the shift.
3
Clean the suction cupsWipe all suction cups with a clean damp cloth to remove glass dust, debris, or moisture. Clean cups last longer and seal better on the next use.
4
Post-use inspectionBriefly inspect the cups, hoses, hook, and controls for any damage that occurred during the session. Note anything to report.
5
Complete the crane logRecord the date, operator name, crane used, materials lifted, and any observations, faults, or near-misses in the crane inspection and operating log. Even minor issues should be logged so patterns can be identified.
10. FAULTS & OUT-OF-SERVICE PROCEDURE
Any of the following conditions requires the crane or vacuum lifter to be immediately taken out of service. Do not allow others to use the equipment until the fault is cleared by a qualified person and the supervisor has approved its return to service.
- Vacuum gauge will not reach or hold the safe operating zone.
- Any suction cup is cracked, torn, hardened, or will not seal.
- Hoist cable or chain shows fraying, kinking, broken strands, or corrosion.
- Hook is cracked, bent, twisted, or the safety latch is missing or non-functional.
- Emergency stop does not function correctly.
- Any crane control does not respond or does not stop when released.
- Any unusual noise, vibration, or movement is observed during operation.
- The crane travels in an unintended direction or at an unintended speed.
- Any structural component appears cracked, bent, or deformed.
Tag the crane or lifter with an out-of-service notice and notify the supervisor immediately. Do not remove the out-of-service tag yourself — it may only be removed by the supervisor or the qualified person who completed the repair.
11. MAINTENANCE SCHEDULE
| Frequency | Task | Performed By |
|---|
| Before first lift of the day | Full pre-use inspection — Sections 7.1 and 7.2 | Operator |
| After each use | Clean suction cups; post-use inspection; complete log | Operator |
| Monthly | Inspect hoist cable/chain; lubricate per manufacturer; check all electrical connections and controls | Supervisor / Qualified Technician |
| Every 6 months | Full mechanical inspection of bridge, trolley, hoist, and vacuum system; replace suction cups if showing wear | Qualified Technician |
| Annually | Manufacturer-recommended service and load test; certification as required by Ontario regulation | Authorised Service Provider |
| As needed | Replace damaged or worn suction cups, hoses, or fittings immediately on discovery | Supervisor / Technician |
NOTE: Ontario Regulation 851 (Industrial Establishments) requires overhead cranes to be inspected and maintained in accordance with the manufacturer's specifications and applicable CSA standards. Ensure annual certification records are kept on file.
12. EMERGENCY PROCEDURES
If the vacuum gauge drops during a lift:
- Stop all crane movement immediately.
- Call out "Glass coming down" loudly and clearly.
- Lower the load to the nearest safe surface as smoothly and quickly as possible.
- Do not attempt to travel the crane to the intended destination — lower first.
- Once the glass is down and the area is safe, investigate the cause before any further lifts.
If glass falls or breaks during a lift:
- Call out "Glass down" immediately. All nearby employees must stop moving and stay still until the breakage has settled.
- Do not rush into the area — assess for falling fragments before approaching.
- Once the area is safe, don cut-resistant gloves and safety glasses before cleaning up.
- Report the incident to the supervisor immediately. Preserve the scene for investigation.
- If anyone is injured, call 911 and administer first aid if trained to do so.
If the crane becomes unresponsive or travels unexpectedly:
- Press the emergency stop button immediately.
- If the load is in the air and the emergency stop has been engaged, do not attempt to restart — call the supervisor.
- Clear all personnel from the area beneath the load until it can be safely recovered.
13. TRAINING & AUTHORISATION
Any trained shop floor employee may operate the overhead cranes and vacuum lifters at Rossen Glass & Mirror Ltd., provided they have completed the following:
- Review and sign acknowledgement of this SOP.
- Receive hands-on orientation on both cranes from a supervisor or experienced operator.
- Demonstrate correct pre-use inspection and a supervised lift before operating independently.
- Renewal orientation required after any recorded crane incident or annually, whichever comes first.
14. REFERENCES & RELATED DOCUMENTS
- Crane and Vacuum Lifter Manufacturer's Operator Manuals (keep on file with equipment)
- Ontario Occupational Health and Safety Act (OHSA), R.S.O. 1990
- Ontario Regulation 851 — Industrial Establishments
- CSA Z150 — Safety Code on Mobile Cranes
- CSA Z142 — Code for Power-Operated Lifting Devices
- SOP SHP-GLS-001 — Glass & Mirror Handling
- Crane Inspection & Operating Log
- Rossen Glass & Mirror Ltd. Incident Reporting Procedure
15. ACKNOWLEDGEMENT & SIGN-OFF
By signing below, all parties confirm they have read, understood, and agree to comply with this Standard Operating Procedure.
| Role | Printed Name | Signature | Date |
|---|
| Operator | | | |
| Supervisor | | | |
| H&S Representative | | | |