Why Boom Trucks Are Often a Risky Choice

[MikePhua]

The Rise of Boom Trucks and Their Design Philosophy
Boom trucks, also known as truck-mounted cranes, emerged in the mid-20th century as a flexible alternative to traditional cranes. Designed to combine mobility with lifting capability, they became popular in utility work, light construction, and equipment delivery. Manufacturers like National Crane, Manitex, and Elliott Equipment Company led the charge, producing thousands of units annually by the 1990s.
Unlike rough terrain (RT) or all-terrain cranes, boom trucks are mounted on standard commercial truck chassis. This allows them to travel at highway speeds and access urban job sites with ease. However, this design comes with trade-offs—especially in terms of stability, lifting capacity, and operator safety.
Top-Heavy Design and Road Hazards
One of the most frequent complaints about boom trucks is their top-heavy nature. With booms often exceeding 120 feet and mounted high to clear the cab, the center of gravity is elevated. This makes the vehicle prone to tipping, especially during sudden maneuvers or tire blowouts.
Key risk factors:

• Long booms without counterweights
  
• High-speed travel (some units run 75 mph with 500 hp engines)
  
• Narrow outrigger footprint compared to RT cranes
  
• Lightweight frames not designed for lateral stress
  

In Missouri, a boom truck tipped over on a highway after a tire failure. The operator survived, but the incident shut down traffic for hours and led to a costly insurance claim. Investigators found that the boom had not been properly stowed and the outriggers were not fully retracted, contributing to instability.
Operator Error and Misuse
Boom trucks often attract operators with limited crane experience. Their truck-like appearance and simplified controls can create a false sense of security. Unlike lattice boom cranes or hydraulic truck cranes, boom trucks are more forgiving in setup—but less forgiving in operation.
Common mistakes include:

• Extending the boom while still in the rest cradle
  
• Overloading without consulting the load chart
  
• Failing to pad outriggers on soft ground
  
• Swinging loads too quickly, causing boom whip
  

In one utility company, a mechanic extended the telescopic boom for greasing while it was still resting on the cradle. The boom buckled under its own weight, resulting in a six-figure repair. Afterward, the company mandated crane operator certification for all service personnel.
Load Moment Indicators and False Confidence
Modern boom trucks are equipped with Load Moment Indicators (LMIs), which monitor boom angle, extension, and load weight. While LMIs are valuable tools, they can be fooled—especially when the boom is resting or the sensors are miscalibrated.
Terminology:

• LMI (Load Moment Indicator): An electronic system that warns operators when approaching overload conditions.
  
• Boom Rest: A cradle that supports the boom during transport or idle periods.
  
• Outrigger Pads: Steel or composite plates placed under outriggers to distribute load and prevent sinking.
  

A safety manager in Washington recalled a case where the LMI failed to register a load properly because the boom was partially supported by the rest. The operator swung the load too quickly, knocking two carpenters off a form during a concrete pour. The incident led to serious injuries and a complete overhaul of the company’s lifting protocols.
Cultural Attitudes and Risk Normalization
There’s a pervasive culture around boom trucks that encourages improvisation. Operators often push limits, citing past success as justification. This mindset leads to dangerous practices like:

• Using oversized concrete buckets without duty cycle reduction
  
• Ignoring wind conditions during long boom lifts
  
• Pouring footings with man baskets or makeshift platforms
  

In Kentucky, a crew attempted to pour footings using a 1.5-yard concrete bucket on a boom truck rated for ¾ yard. The operator refused, citing safety concerns, and was later vindicated when the bucket was found to exceed chart limits by 40%.
Comparing Boom Trucks to True Cranes
While boom trucks have their place, they are not substitutes for purpose-built cranes. RT cranes, for example, have:

• Heavier frames with integrated counterweights
  
• Wider outrigger spreads for stability
  
• Lower boom mounting for better balance
  
• Slower travel speeds but superior lifting control
  

A contractor in Alberta used both boom trucks and RT cranes. He noted that while boom trucks were faster to deploy, they were more prone to tipping and required constant vigilance. His RT crane, though slower, had never experienced a near-miss in five years.
Recommendations for Safer Operation
To mitigate risks, companies should adopt the following practices:

• Require NCCCO or equivalent certification for all boom truck operators
  
• Use steel outrigger pads on every lift, regardless of ground conditions
  
• Perform daily inspections of cables, booms, and hydraulic systems
  
• Limit travel speed when loaded or in adverse weather
  
• Maintain detailed lift plans and enforce load chart compliance
  

Upgrades worth considering:

• Install real-time telematics for boom angle and load tracking
  
• Retrofit automatic outrigger leveling systems
  
• Use anti-two-block devices to prevent cable overextension
  

Conclusion
Boom trucks offer unmatched mobility and convenience, but they come with inherent risks that cannot be ignored. Their top-heavy design, susceptibility to operator error, and cultural normalization of unsafe practices make them a frequent source of accidents. While they serve a niche in light lifting and remote job sites, they should never be treated as full-fledged cranes. With proper training, equipment upgrades, and a shift in mindset, boom trucks can be operated safely—but only when their limitations are fully respected.