Aerial Lift Hazards and What to Watch Out For 2025

Don’t Ignore Boom Lift Hazards in 2025

Boom lift hazards warrant focused attention due to their significant contribution to construction-related fatalities. On average, 26 construction workers die annually from aerial lift incidents, accounting for approximately 2-3% of all construction deaths.

The primary causes include falls, electrocutions (including power lines), falling objects, collapses, equipment tip-overs, and even ejections from the boom lift platform. 

Given these risks, the Occupational Safety and Health Administration (OSHA) emphasizes stringent safety measures for boom lift operations. OSHA mandates comprehensive operator training, adherence to load capacity limits, and the use of personal protective equipment (PPE) to mitigate these hazards and enhance worker safety.

Suppose your business employs construction workers who operate aerial lifts or are consistently around them. In that case, they need to complete an OSHA-approved aerial lift certification course and learn about the man-lift hazards that cause injuries and deaths every year. Enroll your workers in aerial lift safety training, and they’ll be properly prepared to recognize and avoid common hazards associated with aerial lifts.

Common Boom Lift Hazards to Watch Out For

Boom lifts—classified under aerial work platforms (AWPs) or mobile elevating work platforms (MEWPs)—are essential for working at height, but they come with substantial risk if not used properly. According to OSHA, 300 to 400 workers are injured each year in aerial and scissor lift-related accidents, with 20 to 25 fatalities annually.

The majority of serious boom lift accidents involve:

• Falls from height, often due to improper harness use or platform instability

• Tip-overs, caused by exceeding load capacity or operating on uneven surfaces

• Electrocution, from contact with overhead power lines

• Crushing injuries, when workers are caught between the lift and nearby structures

Whether you’re a construction worker, maintenance technician, or site supervisor, recognizing and avoiding these hazards is critical to job site safety. Below are the most common boom lift hazards and tips to prevent serious injury or fatal accidents.

Boom (Aerial) Lift Hazard #1: Electrocutions

In 2017, two of the top 10 OSHA violations involved hazards related to electricity: improper lockout/tagout procedures and electrical wiring methods.

Electrocution remains a leading cause of fatalities among boom lift operators. According to the Occupational Safety and Health Administration (OSHA), numerous incidents occur annually where workers are electrocuted due to aerial lifts contacting overhead power lines. For instance, in August 2023, an employee was fatally electrocuted when the boom lift he was operating contacted a 12kV overhead power line. Source: OSHA

To mitigate the risk of electrocution while operating boom lifts, adhere to the following OSHA-recommended safety practices:

• Maintain Safe Distances: Always assume that all overhead power lines are energized. Maintain a minimum clearance of 10 feet from energized lines up to 50kV, and increase distance accordingly for higher voltages.

• Use Insulated Equipment: Ensure that the boom lift is rated and designed for electrical insulation. However, never rely solely on the equipment’s insulating capability; always maintain appropriate clearances.

• Wear Appropriate Personal Protective Equipment (PPE): Utilize insulated gloves, hard hats, and other protective gear designed for electrical work to provide an additional layer of safety.

• Conduct Thorough Site Assessments: Before commencing work, survey the area for potential electrical hazards, including identifying the presence and location of all overhead power lines.

• Implement Lockout/Tagout Procedures: When working near power lines, ensure that proper lockout/tagout procedures are in place to prevent accidental energization.

By rigorously following these safety protocols and engaging in comprehensive training programs, workers can significantly reduce the risk of electrocution incidents involving boom lifts.

Boom (Aerial) Lift Hazard #2: Falls from Heights

The sheer size of aerial lifts often goes unnoticed until employees begin working. When they are improperly trained, falls can occur. To prevent falls from aerial lifts, workers need to assess their surroundings and make sure there are no objects, other vehicles, or workers nearby that may strike or come in contact with the lift. OSHA requires that all aerial lift workers wear adequate fall protection equipment that includes full-body harnesses and lanyards attached to the lift or basket. Additionally, workers need to do the following: 

• Ensure all access gates or openings are closed when inside the lift basket or platform
• Stand firmly on the floor of the bucket or platform
• Never climb on or lean on the guardrails
• Never use ladders or planks in the working position while in the aerial lift bucket or platform
• Never tie off to structures or poles while in the bucket
• Always adhere to your company’s personal protective equipment (PPE) policies. This includes the proper use of safety harnesses, fall protection equipment, and other devices designed to protect you from falls from heights. 

Some aerial lifts and boom lifts pose serious hazards, simply because they’re so high. If you’re unsure about your specific role and have questions about aerial lift hazards, always keep an open line of communication with your boss, site supervisor, or safety coordinator.

• Always wear fall protection equipment and never belt off to a pole or structure other than the lift’s attachment points.

Boom (Aerial) Lift Hazard #3: Tip-Overs/Collapses

Tip-overs are one of the most deadly types of manlift hazards. They are frequently caused by improper traveling and handling of the lift. Sometimes they are caused by inadequate pre-start vehicle and mechanical inspections. Tip-overs can result from: 

• An exceeded load capacity
• Carrying too large of objects
• Driving the lift with the platform raised
• Exceeding the vertical and horizontal height limits
• Operating the lift in severe weather conditions

Collapses may occur due to mechanical failures and can be prevented by workers completing thorough pre-operation inspections of the vehicle. An inspection can go a long way to ensure that controls are working as intended. If you’re hoping to prevent tip-overs and collapses, make sure not to exceed load capacity limits. Avoid traveling to a job site with your lift raised, and new drive near holes or drop-offs. It’s also important not to raise the platform while you’re on unstable, uneven surfaces. Sloped ground and windy weather can present serious safety hazards in construction.

A widely cited study once illustrated the importance of measures to avoid tip-overs. In this case, a Montana aerial lift worker was killed when his equipment fell over on its side. Despite the potential for numerous violations, OSHA only imposed one on the company, which was a failure to report the accident within eight hours. The bottom line: aerial lift safety is a responsibility everyone shares. Employers, employees, and all personnel involved with workplace safety play a role. Aerial lift hazards – including tip-overs – are waiting to happen. It’s up to alert, properly trained employees to take the steps necessary to avoid injuries and fatalities in the first place. 

Boom (Aerial) Lift Hazard #4: Objects Falling from Lifts

Workers on the ground are at risk of aerial lift hazards, too. They’re sometimes injured and even killed by objects falling from the aerial lift bucket or platform above. This often occurs when lifts are used to carry objects that are larger than the platform itself. If possible, aerial lift operators should avoid positioning the lift underneath overhead objects, and workers on the ground should be aware of their surroundings and avoid working underneath or in close proximity to the lift when it is raised. 

Boom (Aerial) Lift Hazard #5: Ejections from Lift Platform

Ejections are one of the most dangerous types of manlift hazards. They typically happen when a lift comes into contact with another object like a sign or moving vehicle next to a highway, or from inadequate stability assurance. Before operating an aerial lift, workers need to ensure: 

• Outriggers are set on pads or on a level surface on solid ground
• Brakes are set when outriggers are used
• Wheel chocks are used on sloped surfaces when it is safe to do so
• Work zone warnings are set up

An ejection from an aerial lift can occur at any time. However, aerial lift operators who plan accordingly can prevent ejections. 

Boom (Aerial) Lift Hazard #6: Entanglement

Ropes can be tangled up when raising or lowering an aerial lift platform. If entanglement occurs, an operator can get caught up in these ropes. This can put the operator at risk of serious injury or fatality. By staying mindful of all ropes, wires, and cords being used, workers can avoid this all-too-common safety hazard in construction.

Boom (Aerial) Lift Hazard #7: Contact with Objects

Warehouse aerial lift operators can inadvertently come into contact with a ceiling if they are not careful. Meanwhile, aerial lift operators who work near power lines can engage with them, which can result in electrocution. There are also instances when an aerial lift operator does not steer or drive the machine properly. And in these instances, they may strike a building or car. Worst of all, an aerial lift operator may strike a bystander or coworker. Aerial lift hazards like these can be deadly, so it’s important to stay alert to your position while working.

How to Guard Against Common Boom (Aerial) Lift Hazards

There are many things that aerial lift operators can do to protect against manlift hazards. These include:

• Conduct a pre-operation inspection. Evaluate an aerial lift before putting it into use. This requires an operator to verify that all of the lift controls are functioning correctly. An inspection should be performed before using a lift, every time. If any issues are identified, they must be addressed immediately. 
• Operate a lift with precision and care. When controlling and moving an aerial lift, operators must be aware of their surroundings and ensure they have clear visibility of everything on all sides of them, especially when working near a highway. 
• Wear PPE. In all cases, aerial lift operators must always wear adequate fall protection equipment to prevent them from falling from the lift. This involves wearing a full-body harness with a lanyard that is attached to the bucket or platform. 
• Assess the worksite. Keep an eye out for unstable surfaces. Because placing an aerial lift on any of these surfaces can increase the risk of a tip-over. Also, if there is heavy wind or other inclement weather conditions, ensure that workers do not use an aerial lift until the conditions improve. 

These are only a handful of ways to guard against aerial lift hazards. Perhaps the best strategy is to educate yourself and your colleagues. It’s not just a good idea – it’s the law. 

The Impact of Proper Manlift Training

Simply put, an aerial lift operator with little or no training is an accident waiting to happen. The best way to prevent costly aerial lift hazards is to hire or train qualified AWP workers. All U.S. employers are required by OSHA to train their employees. This presents many problems, from budget to scheduling and more. Thankfully, CertifyMeOnline.net has a great selection of aerial lift and scissor lift courses to help get you OSHA compliant in no time!

Proper training is vitally important for safe, efficient AWP operation. The more you know, the better you’re prepared to handle those tough on-the-job situations. And with fines and penalties reaching upwards of $20,000, there is a smart financial incentive for your company to ensure thorough training as well.

With CertifyMeOnline.net, all of your training needs are accounted for. Our OSHA-aware modules and superior instruction cover all the bases. Along with AWP training, we also offer courses for boom lifts, fall protection, scissor lifts, and much more.

Protect Your Workers Against Manlift Hazards

Many of the most common aerial lift hazards are directly related to one of the most widely-cited OSHA violations: fall protection training requirements. By providing your workers with OSHA-approved training, you can protect them against falls and other on-the-job dangers. 

CertifyMeOnline.net provides users with a solid base of knowledge in all aspects related to safe, efficient aerial lift operations. If you’d like to learn more about aerial lift hazard safety training, please call our OSHA training experts today at (602) 277-0615 or reach out online. We look forward to helping you and your company become OSHA-compliant.