Crane Safety & Operation Requirements Malaysia: DOSH Registration, Inspection & Compliance

Crane accidents are among the most fatal incidents on Malaysian construction sites and factories. Research from Universiti Teknologi Malaysia found that the most common cause of tower crane failures is operation by non-competent persons. The most common mechanical failure is boom or jib failure. Both are preventable with proper compliance.

This guide covers crane safety from registration to daily operations: what DOSH requires, how to ensure your operators and equipment are compliant, and the operational safety procedures that prevent accidents on site.

This guide covers:

• Types of cranes and their regulatory classification
• DOSH registration and Certificate of Fitness (CF) requirements
• Crane operator certification (Perakuan Kuasa)
• Daily pre-operation inspection checklist
• Rigging and slinging safety requirements
• Common causes of crane accidents in Malaysia
• Environmental and site condition considerations
• Insurance requirements for crane operations

Disclaimer: This article provides general guidance based on the Occupational Safety and Health Act 1994, the OSH (Plant Requiring Certificate of Fitness) Regulations 2024, and DOSH guidelines as of February 2026. Regulations may be amended. Always verify current requirements with DOSH or qualified professionals before making compliance decisions.

Types of Cranes and Regulatory Classification

Not all cranes have the same risk profile or regulatory requirements. The type of crane determines the Certificate of Fitness category, operator certification class, and inspection schedule. Understanding these categories is the first step in compliance.

Crane Type	Typical Use in Malaysia	Capacity Range	CF Required
Tower Crane	High-rise construction, large building projects	3-20 tonnes	Yes
Mobile Crane (truck-mounted)	General construction lifting, equipment installation	10-500 tonnes	Yes
Crawler Crane	Heavy lifting on soft ground, infrastructure projects	50-3,000 tonnes	Yes
Overhead (Bridge) Crane	Factories, warehouses, workshops	1-50 tonnes	Yes
Gantry Crane	Ports, shipyards, container yards	5-100+ tonnes	Yes
Jib Crane	Workshop loading, production line material handling	0.5-5 tonnes	Yes
Lorry Loader (HIAB)	Delivery and loading at construction sites	1-20 tonnes	Yes

DOSH Registration and Certificate of Fitness

Every crane in Malaysia must have a valid Certificate of Fitness (CF) issued by DOSH before it can be operated. Since 1 June 2024, crane registration falls under the Occupational Safety and Health (Plant Requiring Certificate of Fitness) Regulations 2024, replacing the old PMA system under the Factories and Machinery Act 1967.

For the full step-by-step CF process, including design verification, load testing standards, and renewal procedures, see our detailed guide on lifting equipment inspection requirements in Malaysia.

CF Requirement	Details
Legal basis	OSH (Plant Requiring Certificate of Fitness) Regulations 2024 under OSHA 1994
CF validity	15 months (standard); up to 60 months under Special Scheme of Inspection
Renewal application	Via MyKKP online system (mykkp.dosh.gov.my)
Inspection	By DOSH officer or DOSH-licensed inspector
Load test (new equipment)	125% of Safe Working Load (SWL)
Load test (renewal)	110-125% of SWL depending on equipment age and condition
Penalty for operating without CF	Fine up to RM100,000 or imprisonment up to 1 year, or both; continuing offence: up to RM1,000 per day

Crane Operator Certification (Perakuan Kuasa)

Operating a crane without proper certification is both illegal and the leading cause of crane accidents in Malaysia. Every crane operator must hold a valid Perakuan Kuasa (Certificate of Competency) issued by DOSH for the specific class of crane they operate.

Requirement	Details
Minimum age	18 years old
Training	Completed at DOSH-recognised Crane Operator Training Centre
Medical fitness	Must pass medical examination including vision, hearing, and physical fitness
Theory and practical test	Must pass both components administered by DOSH-recognised centre
Certificate validity	3 years
Renewal requirements	Refresher course and medical examination before expiry
Equipment specificity	Certification is class-specific; tower crane operator can't operate mobile crane without separate certification

DOSH maintains a list of approved Crane Operator Training Centres on their website. You can verify an operator's certification status through DOSH's online portal. Always verify before allowing anyone to operate your crane.

Operator Classes

Operator Class	Equipment Covered
Tower Crane Operator	All tower crane types (top-slewing, flat-top, luffing jib)
Mobile Crane Operator	Truck-mounted cranes, rough terrain cranes
Crawler Crane Operator	Crawler-mounted cranes
Overhead Crane Operator	Bridge cranes, gantry cranes

Daily Pre-Operation Inspection

Every crane must be inspected before each shift. This isn't just best practice; it's a legal requirement. The operator must not use the crane if any defect is found that could affect safe operation. Document every inspection.

Category	Inspection Items
Structural	Boom/jib condition, visible cracks or deformation, bolt tightness, counterweights secure
Wire ropes and chains	Fraying, kinking, broken strands, correct reeving, proper lubrication
Hook and block	Safety latch functioning, no cracks or throat opening, free rotation
Safety devices	Load moment indicator (LMI), anti-two-block device, limit switches (hoist, travel, swing), anemometer (tower cranes)
Electrical	Cable condition, emergency stop function, warning lights and horn, pendant control
Hydraulic (mobile cranes)	Oil levels, hose condition, no visible leaks, outrigger function
Ground conditions	Outrigger pads on stable ground, no underground voids, adequate ground bearing capacity
Environmental	Wind speed within limits, visibility adequate, no electrical power lines within swing radius

Safe Lifting Operations: Planning and Execution

Every lift should be planned before execution. For routine lifts, a standard lifting procedure may suffice. For heavy, complex, or tandem lifts, a formal lift plan prepared by a competent person is required.

Lift Planning Requirements

Lift Category	Criteria	Planning Requirement
Routine lift	Load weight well below SWL, familiar operation, clear area	Standard procedure, operator assessment, toolbox talk
Complex lift	Load >75% of rated capacity at given radius	Written lift plan by competent person, method statement, risk assessment
Critical/heavy lift	Load >80% SWL, tandem lift, lifting near structures, or over occupied areas	Detailed lift plan with calculations, engineering approval, dedicated safety personnel, exclusion zones
Tandem lift	Two or more cranes lifting a single load	Engineered lift plan mandatory, load distribution calculations, synchronised communications

Load Chart Compliance

Every crane has a rated capacity that varies with boom length and radius. The load chart is the most important safety reference for any crane operation. Operating outside the load chart parameters is the fastest way to cause an overload and tip-over.

Load Chart Factor	What It Affects	Common Mistake
Working radius	Maximum load decreases as radius increases	Not accounting for load swing increasing the effective radius
Boom length	Longer boom reduces capacity at any given radius	Using maximum boom without checking reduced capacity
Ground slope	Out-of-level crane reduces rated capacity	Setting up on unlevelled ground without de-rating
Rigging weight	Slings, shackles, spreader bars reduce net lifting capacity	Not deducting rigging weight from available capacity
Wind loading	Wind on load and boom adds to effective load	Lifting large surface-area loads in wind without de-rating

Rigging and Slinging Safety

Rigging failures cause a significant portion of crane-related accidents. The rigger or signalman is as important to crane safety as the operator. All rigging equipment must be inspected before each use and have a known Safe Working Load.

Rigging Equipment	Inspection Points	Rejection Criteria
Wire rope slings	Broken wires, corrosion, kinks, diameter reduction	6+ broken wires in one lay length; 10% diameter reduction
Chain slings	Stretch, wear, cracks, link deformation	5% elongation; visible cracks; twisted links
Webbing slings	Cuts, abrasion, chemical damage, stitching integrity	Any cut exceeding 10% of width; chemical exposure; faded colour code
Shackles	Pin condition, body deformation, thread integrity	Bent pin; worn threads; missing SWL marking
Spreader beams	Structural integrity, connection points, SWL marking	Visible cracks; missing load test certificate; no SWL plate

Sling Angle Factor

The angle of a sling directly affects how much load each leg carries. This is one of the most commonly misunderstood aspects of rigging. As the angle decreases from vertical, the tension in each sling leg increases dramatically.

Sling Angle from Vertical	Load Factor per Leg	Effect on 2-Leg Sling Capacity
0° (vertical)	1.00	100% of rated capacity
30°	1.15	87% of rated capacity
45°	1.41	71% of rated capacity
60°	2.00	50% of rated capacity

Never use slings at angles greater than 60 degrees from vertical. At 60 degrees, each sling leg carries the full weight of the load. Beyond that, you're exceeding the sling's capacity even though the load itself hasn't changed.

Common Causes of Crane Accidents in Malaysia

Research from Malaysian universities and DOSH investigation reports reveal consistent patterns in crane accidents. Understanding these causes is the first step in prevention.

Cause Category	Specific Causes	Prevention
Human error (most common)	Uncertified operator, disobeying safety procedures, lack of communication, poor supervision	Verify Perakuan Kuasa, enforce SOP compliance, appointed signal persons, competent supervision
Overloading	Exceeding rated capacity, not checking load chart, unknown load weight	Weigh all loads before lifting, verify against load chart at actual radius, use load moment indicator
Mechanical failure	Boom/jib failure, wire rope failure, hydraulic failure, brake failure	Maintain valid CF, conduct daily inspections, scheduled maintenance per manufacturer recommendations
Ground failure	Soft ground, inadequate outrigger pads, underground voids, slope instability	Ground bearing assessment, proper outrigger timber pads, avoid setup near excavations
Environmental	High winds, lightning, poor visibility, contact with power lines	Anemometer monitoring, cease operations above 72 km/h (tower cranes), maintain clearance from power lines
Rigging failure	Wrong sling selection, damaged rigging, incorrect sling angle, no tag lines	Pre-use rigging inspection, trained riggers, sling angle awareness, tag lines on all loads

Environmental and Site Conditions

Malaysia's tropical climate creates specific challenges for crane operations. Afternoon thunderstorms, monsoon rains, and high humidity affect crane safety differently than temperate climates.

Condition	Risk	Required Action
Wind speed >72 km/h	Tower crane structural risk, load swing	Cease all operations, park crane in weathervane position, secure boom
Wind speed 50-72 km/h	Reduced control, load drift	Cease lifting large surface-area loads, reduce capacity, increase supervision
Lightning	Direct strike on crane (highest point on site)	Cease operations, evacuate crane, maintain lightning protection system
Heavy rain	Reduced visibility, slippery surfaces, soft ground	Cease if visibility below safe limits, reassess ground conditions after heavy rain
Proximity to power lines	Electrocution (fatal on contact)	Minimum clearance: 3m for up to 33kV; contact TNB for lines >33kV; use proximity alarms
Soft/saturated ground	Outrigger sinking, crane tipping	Geotechnical assessment, use outrigger mats/pads, timber cribbing

Signal Person Requirements

When the crane operator cannot see the load or the landing area, a designated signal person must guide the operation. Signal persons must be trained in standard hand signals and have clear communication with the operator.

Signal	Hand Signal Description
Hoist (raise)	Forearm vertical, index finger pointing up, rotate hand in small circles
Lower	Arm extended downward, index finger pointing down, rotate hand in small circles
Stop	Arm extended, palm down, move hand horizontally back and forth
Emergency stop	Both arms extended, palms down, move both hands horizontally back and forth
Swing (slew)	Arm extended, point with finger in direction of swing
Travel	Arm extended forward, palm up, making pushing motion in direction of travel

For complex lifts or when distance prevents visual hand signals, two-way radio communication is required. Only one person should give signals to the operator at any time.

Crane Exclusion Zones

Establishing and enforcing exclusion zones is one of the most effective ways to prevent crane-related fatalities. The most common victims of crane accidents aren't the operators; they're ground workers caught in the drop zone.

Zone	Definition	Access Control
Swing radius zone	Area swept by the crane's counterweight during slewing	Physical barriers (concrete blocks, steel bollards); no workers within zone during operation
Drop zone	Area directly below the load path and surrounding area accounting for load swing	Barricade tape, cones, banksman to control access; never walk under a suspended load
Outrigger zone	Area around mobile crane outriggers	Clear area around outriggers; no traffic or workers near outrigger footprints
Power line zone	Minimum clearance distance from overhead power lines	3m minimum for up to 33kV; contact utility provider for higher voltages

Insurance Requirements for Crane Operations

Crane operations create concentrated risk: high-value equipment, potential for catastrophic damage, and injury to multiple workers simultaneously. Your insurance programme needs to address each of these.

Insurance Type	What It Covers for Crane Operations	Key Considerations
CAR/EAR Insurance	Damage to works being constructed, crane damage during project	Ensure construction plant is included; some policies limit crane coverage to specified SWL
Machinery Breakdown	Mechanical and electrical breakdown of the crane itself	Valid CF is typically a policy condition; lapsed CF may void coverage
CGL Insurance	Third-party injury or property damage from crane operations	Ensure adequate limits; crane incidents can cause damage to neighbouring properties and public
Workmen Compensation	Worker injuries from crane accidents	Crane accidents often cause fatal or serious injuries; ensure adequate limits per worker

A valid CF is typically a policy condition for crane insurance. If your crane is involved in an incident and the CF has lapsed, your insurer may deny the claim. Similarly, using an uncertified operator may be treated as a breach of policy conditions. Keep your compliance documentation current.

Crane Safety Compliance Checklist

Item	Yes/No
All cranes have valid Certificate of Fitness (CF) from DOSH
All crane operators hold valid Perakuan Kuasa for the correct crane class
Daily pre-operation inspections documented in logbook
Load charts available and legible at operator station
Safety devices tested and functional (LMI, limit switches, anemometer)
Rigging equipment inspected and within SWL
Exclusion zones established and enforced during lifting
Trained signal persons assigned for blind lifts
Lift plans prepared for complex/heavy lifts
Wind speed monitoring in place for tower cranes
Power line clearance verified and maintained
Insurance coverage verified with valid CF attached

FAQ

Does every crane in Malaysia need a Certificate of Fitness?

Yes. Every crane, hoist, and lifting machine must have a valid CF from DOSH before operation. This applies to tower cranes, mobile cranes, crawler cranes, overhead cranes, gantry cranes, and jib cranes. The CF is valid for 15 months and must be renewed through the MyKKP system. For the full CF process, see our lifting equipment inspection guide.

What is the penalty for operating a crane without a valid CF?

A fine up to RM100,000 or imprisonment up to 1 year, or both. For continuing offences, an additional fine of up to RM1,000 per day. If an accident occurs while operating without CF, the penalties escalate significantly, and your insurance claims may be denied.

How often must crane operators renew their certification?

Every 3 years. Renewal requires attending a refresher course at a DOSH-recognised training centre and passing a medical examination. Operators must apply for renewal before their Perakuan Kuasa expires. Operating with an expired certification is treated the same as operating without certification.

Can a tower crane operator operate a mobile crane?

No. Perakuan Kuasa is class-specific. A tower crane operator must obtain a separate certification to operate a mobile crane, crawler crane, or overhead crane. Each class requires its own training course and competency assessment.

When should crane operations stop due to wind?

Tower crane operations should cease when sustained wind speeds exceed 72 km/h. At 50-72 km/h, lifting of large surface-area loads (panels, formwork) should stop. The crane's anemometer provides real-time wind speed readings. Below 50 km/h, you should still de-rate capacity for wind loading on the load and boom.

What is the minimum safe distance from power lines during crane operations?

Minimum 3 metres clearance from overhead power lines up to 33kV. For higher voltage lines, contact Tenaga Nasional Berhad (TNB) for specific clearance requirements. Electrocution from contact with power lines is one of the most common causes of crane fatalities. Consider using proximity warning devices and appointing a dedicated spotter.

Who is responsible for crane safety on a construction site?

The main contractor typically bears primary responsibility under OSHA 1994. But the crane owner, operator, and riggers all have specific duties. The occupier of the workplace (factory owner for overhead cranes) is responsible for maintaining valid CF and ensuring competent operation. Subcontractors bringing cranes to site must ensure their equipment has valid CF and operators hold valid Perakuan Kuasa.

What insurance do I need for crane operations?

CAR insurance covers damage to the works from crane incidents during construction. Machinery breakdown insurance covers the crane itself. CGL insurance covers third-party injury and property damage. Workmen compensation covers worker injuries. Most policies require valid CF as a condition of coverage.

How do I verify a crane operator's certification?

DOSH maintains an online database of certified crane operators accessible through their portal at dosh.gov.my. Request the operator's Perakuan Kuasa card and verify the details against DOSH records. Check the validity date, crane class, and photo ID match. Never take a photocopy at face value; verify directly with DOSH.

What should I do if a crane fails its CF inspection?

The crane must not be operated until all deficiencies are rectified. Address the specific issues identified by the inspector, arrange for repairs by qualified technicians, and schedule a re-inspection. Common failure points include worn wire ropes, non-functioning safety devices, structural corrosion, and hydraulic system leaks.

Foundation Conclusion

Crane safety in Malaysia depends on three pillars: registered equipment (valid CF), certified operators (valid Perakuan Kuasa), and proper operational procedures. DOSH's 2024 regulatory update under OSHA 1994 reinforced these requirements with higher penalties and broader coverage.

Crane accidents create some of the most costly insurance claims in construction and manufacturing. A single tower crane collapse can damage the entire project, injure multiple workers, and affect neighbouring properties. CAR insurance and machinery breakdown coverage protect your investment, but only if your compliance documentation is current.

Talk to our risk specialists about construction and machinery insurance