Working at height using a cherry picker — also known as a boom lift or mobile elevating work platform (MEWP) — can be efficient and productive. But it can also be fatal if safety is ignored. Most cherry picker accidents stem not from equipment failure but from human error and inadequate safety measures. So, how can workers and supervisors ensure safe operation while maximizing productivity?
The question this article answers is simple: What are the most essential cherry picker safety tips every worker must follow to prevent injuries and fatalities?
The answer lies in practical application of risk controls, proper training, and a proactive safety culture — all of which we’ll cover in detail through proven safety tips that are often overlooked but crucial for everyday operations.
Why Cherry Picker Safety Is Non-Negotiable
Cherry pickers help workers reach otherwise inaccessible areas, from electrical poles to warehouse ceilings and construction façades. Yet their use comes with inherent hazards — including falls, tip-overs, electrocution, entrapment, and collisions. The Health and Safety Executive (HSE UK) and OSHA (USA) have both reported fatalities involving cherry pickers where basic precautions were not taken.
For example, OSHA records indicate that improper fall protection is one of the leading causes of death in MEWP-related tasks (OSHA, 2024). Therefore, safety should never be a reactive measure — it must be built into every step of operation.
Cherry Picker Safety Tips
1. Conduct a Thorough Pre-Operation Inspection
Before operating a cherry picker, always complete a detailed pre-use inspection. This should include:
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Checking hydraulic systems for leaks
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Verifying tire or track condition
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Ensuring the emergency lowering system is functional
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Confirming the battery and fuel levels are adequate
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Testing the control panel and safety switches
Don’t rely solely on visual inspections. Use a manufacturer-approved checklist and record findings. If faults are found, lockout/tagout the equipment until repairs are made. This simple habit prevents sudden malfunctions mid-air — one of the most common cherry picker hazards.
Unique Insight: Many operators skip pre-inspections if the same machine was used “yesterday without issues.” This false sense of security is where accidents begin. Inspect every time — regardless of prior use.
2. Use the Right Type of Cherry Picker for the Job
Cherry pickers are not one-size-fits-all. Using the wrong lift for a task can create serious safety risks.
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Articulating boom lifts are ideal for reaching over obstacles.
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Telescopic booms offer higher reach but less maneuverability.
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Towable lifts are best for light-duty or occasional work.
Evaluate the site terrain, required height, proximity to power lines, and load weight. Choosing the right machine reduces strain and improves operator control.
Unique Insight: On many construction sites, telescopic lifts are used in tight spaces due to their height advantage — a common yet dangerous mismatch. Always match machine capabilities to task demands.
3. Conduct Site-Specific Risk Assessments
Cherry picker safety doesn’t stop with the equipment — the worksite matters just as much. A full risk assessment should include:
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Surface stability (slopes, soft ground, potholes)
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Overhead obstructions (power lines, scaffolding)
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Wind speed and weather conditions
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Traffic movement or other active machinery
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Access routes and emergency evacuation paths
According to the International Powered Access Federation (IPAF), over 35% of MEWP incidents occur due to poor site assessments (IPAF, 2024).
Pro Tip: Use cones or barriers to isolate the cherry picker from pedestrian or vehicle traffic.
4. Ensure All Operators Are Competently Trained and Certified
No one should operate a cherry picker without documented training that covers:
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Equipment controls
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Emergency procedures
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Load limits and balance
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Fall protection systems
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Safe maneuvering techniques
In the U.S., OSHA requires MEWP operators to complete ANSI A92.24-compliant training. In the UK, IPAF PAL cards certify competence. Make sure training is refreshed every 3–5 years or when new equipment is introduced.
Unique Insight: Training should also include real-time hazard simulations — such as wind gust scenarios — to prepare workers for unpredictable variables.
5. Wear the Correct Personal Protective Equipment (PPE)
Fall protection is non-negotiable when working in a cherry picker. At a minimum, wear:
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A full-body harness
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A short lanyard (to prevent ejection during a fall)
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A helmet with a chin strap
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High-visibility clothing
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Non-slip footwear
Ensure that the lanyard is attached to an approved anchor point inside the platform — not the guardrails. OSHA and HSE strictly mandate proper anchorage during aerial work.
Cautionary Note: Fall arrest systems are often misused. The lanyard should not be long enough to allow a fall out of the basket — it’s a fall restraint, not a catch net.
6. Check Weather Conditions Before and During Use
Strong wind and rain can destabilize a cherry picker, especially when extended to maximum height. OSHA suggests that operations be stopped if winds exceed 28 mph (12.5 m/s).
Also, avoid using cherry pickers during:
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Lightning
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Heavy snow or sleet
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Ice formation on equipment
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Thick fog or low visibility
Weather can change rapidly. Assign someone to monitor real-time forecasts and alert the crew.
Unique Insight: Use an anemometer (wind speed meter) on the cherry picker — a surprisingly underused tool — to measure conditions at height, not ground level.
7. Respect Load Limits and Platform Capacity
Each cherry picker has a manufacturer-rated capacity, typically between 200–450 kg (440–990 lbs), depending on the model. Overloading risks:
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Structural failure
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Tip-over
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Control instability
Also, consider dynamic loads — such as the force of tools dropped onto the floor or workers shifting position quickly. Never carry materials that exceed the rated load, and always distribute weight evenly.
Tip: Account for the weight of PPE, tools, and multiple workers — not just “headcount.” Most overloading occurs due to oversight, not intention.
8. Never Move the Cherry Picker While Elevated (Unless Designed To)
Some cherry pickers, such as certain self-propelled models, are designed for movement while the boom is raised. But many are not. Moving a non-self-propelled cherry picker when extended can cause:
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Loss of balance
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Tip-over on uneven surfaces
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Shear-force damage to the lift base
Check the manufacturer’s manual before moving an elevated unit. Use spotters if navigating tight or congested areas.
Warning: In several recorded accidents, workers moved an extended lift over a pothole — causing catastrophic tipping. This is entirely avoidable.
9. Stay Clear of Power Lines and Overhead Hazards
Electrocution is one of the top three causes of death in MEWP operations. OSHA mandates a minimum distance of 10 feet (3 meters) from energized lines under 50 kV, and greater for higher voltages.
Cherry picker operators must also watch out for:
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Tree branches
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Scaffolding
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Ceilings and light fixtures
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Crane booms
Use a designated ground observer if the operator’s view is restricted.
Pro Tip: Use insulated cherry pickers when working near electrical lines — but insulation doesn’t guarantee protection. Always de-energize lines when possible.
10. Avoid Entrapment and Crushing Hazards
Entrapment accidents occur when workers get crushed between the lift and overhead structures — like beams or walls. To reduce this risk:
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Maintain proper distance from overhead structures
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Avoid sudden boom movements
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Install anti-entrapment devices (e.g., pressure-sensitive bars)
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Use a spotter to monitor blind spots
Entrapment is often silent and fast — the operator might not have time to react. Prevention is key.
Unique Insight: One worker fatality occurred because he leaned over the controls while extending the boom — pinning himself against the ceiling. Awareness and spacing save lives.
11. Establish Emergency Procedures and Rescue Plans
Despite all precautions, things can go wrong. Having an emergency plan can mean the difference between injury and fatality. Make sure to:
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Train workers in emergency descent systems
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Assign an on-site rescue-trained responder
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Keep communication tools (radios, phones) at hand
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Know the local emergency services number
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Maintain access for emergency vehicles
Never assume “help will arrive.” Be prepared to self-rescue or initiate a coordinated response.
Tip: Practice rescue drills at least quarterly. Many teams go years without real drills — then freeze in actual emergencies.
Final Thoughts: Make Safety a Culture, Not a Checklist
The difference between a safe and a hazardous cherry picker operation often lies in mindset, not just compliance. When safety is seen as a task to “get through,” shortcuts happen. But when safety becomes part of the work culture — reinforced by leadership, planning, and empowerment — accidents drop, and productivity soars.
Implementing these 11 cherry picker safety tips won’t just meet regulatory requirements — it will build a foundation of trust, skill, and accountability on your worksite.
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