Cranes are an essential part of any loading operation. As common as they are, though, these machines can pose significant safety risks. While that may not be surprising — they involve extreme heights and heavy loads, after all — it still deserves attention.

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New technologies offer a solution to these hazards. Autonomous cranes are becoming an increasingly common sight, although they’re still relatively new. Despite this novelty, robotic lifters could significantly improve shipyards and warehouses.

Autonomous Cranes in Logistics Today

The transportation and logistics sector has not embraced automation as readily as other sectors, but that’s changing. While just 18% of warehouses used some form of automated technology in 2021, experts predict one-quarter of them will by 2027.

Material handling systems account for much of the industry’s automation. Autonomous guided vehicles (AGVs) take a lot of the spotlight in this area, but robotic cranes have emerged as a promising alternative. Manual cranes are already common throughout the industry — especially in shipyards — so businesses wouldn’t need to adapt much to use automated versions. AGVs also can’t carry heavy loads or freight containers like cranes can, so many organizations may need to use both.

As this technology has become more accessible, it’s starting to pop up more in logistics operations. Railroad company Union Pacific deployed five autonomous cranes in 2021 to move freight onto and off of rail cars. Ports in Australia, China and the Netherlands have invested in these systems since as early as 2014, resulting in higher capacity and lower costs.

Autonomous Cranes Could Improve Safety

The primary advantage of automated cranes in logistics is they distance employees from the most dangerous parts of the job. Operators account for over half of all crane-related deaths in the transportation sector. Removing the need for a human controller instantly eliminates those fatalities — injuries from being in the equipment are impossible when no one is in the cab.

Of course, lifting equipment can still endanger nearby dock and warehouse workers. Autonomous technology addresses these concerns, too. While robotic cranes may not remove falling object or collision hazards entirely, they reduce them by minimizing mistakes.

Studies suggest between 80% and 90% of all workplace accidents stem from human error. Automation may not be perfect, but it is less likely to make the same mistakes. It operates based on consistent, real-time data and cannot get tired or distracted.

Most autonomous lifting equipment today still requires employees to oversee its operations, especially in busy ports, where risks are higher. However, minimizing the human element reduces error-related hazards. Combining the reliability of automation with people’s intuition and nuance could offer the best of both worlds. Expert operators would make up for robots’ occasional lapses and vice versa.

Autonomous Crane Risks

At the same time, autonomous cranes are not without risk. In some cases, they may introduce new safety concerns. Businesses must pay attention to these hazards to take full advantage of this technology.

The biggest concern with automated material handling is teams could become complacent. Operators may assume — even subconsciously — that robotic lifters are more reliable than they are. As a result, they may pay less attention to their surroundings, making injuries more likely if something goes wrong in the automated system. The logistics sector’s already strained workforce may exacerbate these risks.

There are also technical glitches and limitations to consider. Automation’s precision benefits only apply when the sensors it relies on work properly. That’s not an issue for cranes in warehouse environments but may pose problems on outdoor docks or loading bays. High winds — which are increasing at a rate of 2.58% per decade — are particularly concerning. Sensors failing to account for sudden gusts could lead to dangerous situations.

Using Autonomous Cranes Safely

In light of these potential downsides, businesses should take several precautions when implementing autonomous machinery. Like with any lift, teams should plan automated crane operations ahead of time. 3D simulation software can help here, as it automatically recalculates load capacities each time users change other data points. This precision makes it easier to ensure a safe lift.

Regular equipment inspections are likewise essential, as they are the second most frequently cited crane-related OSHA violations. Employees should check cranes for signs of wear and calibrate their sensors before every job to verify the machinery will work properly. Maintenance sensors can streamline this process by alerting operators of emerging issues as soon as they arise.

Even though automation minimizes human involvement, staff-centric steps are still necessary. Operators overseeing autonomous workflows need thorough training and regular re-certification to ensure their continued awareness. Similarly, brands should communicate any new workflow considerations or hazards automation may introduce to help everyone remain vigilant.

No automated system should be able to work without human supervision. Consequently, teams must follow strict lockout-tagout procedures after running autonomous lifting equipment. These steps must include lowering lift arms or otherwise moving large parts out of the way to minimize hazards.

As organizations use autonomous cranes more often, they may discover new, unique risks. As a result, safety protocols may need to adjust over time. Regular reviews and workplace accident audits will reveal when such adaption is necessary.

New Technology Is Changing the Future of Workplace Safety

Autonomous cranes could revolutionize workplace safety. However, they’re not entirely risk-free. Enterprises must pay attention to both sides to capitalize on technology safely.

Learning how new tech can help or hinder worker safety is the first step to becoming a safer, more efficient industry. The sector as a whole will become a better place to work if enough companies take a calculated, careful approach to automation.