Key Takeaways
- AI‑based video analytics (ViAct, Glodon) can cut tower‑crane accidents by up to 95 % and lower manpower needs by ~70 %.
- Real‑time alerts are generated within one second of detecting unsafe acts such as missing PPE, unauthorised entry, or proximity hazards.
- Heat‑stress monitoring using ViAct’s AI has shown a 63 % drop in heat‑related medical cases and 95 % compliance with hydration/rest schedules in Singapore pilots.
- Glodon’s Smart Crane Guardian goes beyond collision avoidance, enabling remote‑operator control from a ground‑level dashboard.
- AMCS’s DCS 61‑S/61‑M systems use multi‑constellation GNSS and programmable geo‑fences to protect both tower and mobile cranes across changing sites.
- The Buddie System offers a low‑tech, physical lanyard‑link that guarantees immediate, unambiguous communication between ground crews and crane operators.
- Potain’s TT3 (Top Tracing) anti‑collision platform can network up to 16 cranes, manage 30 prohibited zones, and is backward compatible with earlier TT1 hardware.
AI‑Driven Video Analytics for Crane Safety
ViAct, a Hong Kong‑based firm, supplies a machine‑ and system‑agnostic AI platform that ingests existing CCTV feeds and processes them on‑site with Edge AI processors dubbed ViMOV. Leveraging a library of more than 200 computer‑vision modules, the system instantly recognises unsafe conditions such as missing safety gear, unauthorised zone incursions, or workers standing too close to moving loads. When a violation or near‑miss is flagged, ViAct pushes an audio‑visual alert or mobile push notification to supervisors within one second, and all data is archived in the cloud for later auditing. The company claims that deployment yields “a 95 per cent reduction in accidents” and “a 70 % reduction in manpower costs,” figures that underscore the transformative potential of real‑time AI monitoring on busy construction sites.
Heat‑Stress Management Through AI
Beyond basic safety violation detection, ViAct is piloting an AI‑driven heat‑stress module across Singaporean projects. The system analyses video cues to estimate when a worker is approaching a dangerous heat‑stress threshold, aligning with the Ministry of Manpower’s Wet Bulb Globe Temperature (WBGT) guidelines. Early results are encouraging: “Early deployments of the new ViAct feature has resulted in a 63 % reduction in heat‑related medical cases and 95 % adherence to hydration and rest schedules.” By automating the monitoring of physiological risk factors, ViAct helps contractors meet regulatory requirements while protecting workers from heat‑related illness—a growing concern in tropical climates.
Glodon’s Smart Crane Guardian: Anti‑Collision and Remote Operation
Glodon, a China‑based developer of AI solutions for construction, building design, power and education, offers the Smart Crane Guardian system. The platform fuses data from a network of sensors and high‑definition cameras to drive an anti‑collision engine. Before a crane enters an overlapping work zone, the system warns the operator and reduces speed; if the maneuver continues toward imminent contact, it can bring the crane to a full stop. A notable advancement is the ability to “remove the operator from the tower crane,” allowing personnel to control the lift from a ground‑level dashboard that displays multi‑dimensional operations in real time. This remote‑operator capability not only shields crews from the heavy‑lift environment but also promises gains in both efficiency and safety.
AMCS Technologies: Scalable Anti‑Collision for Tower and Mobile Cranes
AMCS Technologies, a French safety‑solutions provider with three decades of experience, markets the DCS 61‑S anti‑collision and zoning system for tower cranes and the DCS 61‑M variant for mobile cranes. In a 2025 interview, Radoine Bouajaj, AMCS sales director, reflected on the product’s evolution: “Our first anti‑collision systems were designed to be reliable and user friendly. Over time we have evolved the technology to become more intelligent, precise and integrated. Each generation has improved safety, usability and adaptability.” The system relies on high‑precision multi‑constellation GNSS positioning, allowing users to define no‑go and restricted areas via geometric shapes or polygons that can be toggled on‑the‑fly. For mobile cranes, which face constantly shifting site layouts, this continuous location monitoring is essential to avoid collisions with structures, other equipment, or personnel.
Buddie System: A Physical Link for Immediate Communication
Contrasting the sensor‑heavy AI approaches, the Buddie System adopts a deliberately simple, physical methodology. Skilled site managers hold a lanyard attached to a signalling device; pulling the lanyard sends an instant, hard‑wired alert to the crane operator, prompting a pre‑programmed response such as slowing down or stopping the lift. Up to ten lanyards can be paired to a single crane‑mounted alert unit, with an effective range of roughly 1,000 metres, and multiple devices can operate simultaneously on a site. As the article notes, “the physical connection between the ground crew and crane operator removes any potential for a communication to be missed or misinterpreted.” This low‑tech solution guarantees that critical safety signals are conveyed without reliance on wireless networks, software latency, or power‑dependent electronics.
Manufacturer‑Integrated Safety: Potain’s TT3 (Top Tracing) System
Crane original equipment manufacturers are also embedding safety intelligence directly into their products. Potain’s TT3 (Top Tracing) anti‑collision system exemplifies this trend. The platform can network up to 16 cranes on a single radio‑frequency chain while actively monitoring and enforcing up to 30 prohibited zones. Sensors read RFID tags affixed to each crane to compute inter‑crane proximity, enforce hook‑height limits within restricted areas, manage travel‑track constraints, and incorporate wind‑speed data into safety calculations. If more than 16 cranes are required, an additional frequency can be added, and the TT3 remains backward compatible with the earlier TT1 hardware. The system is available for Potain’s CCS (Crane Control System) self‑erecting and top‑slewing cranes, offering a tightly integrated, manufacturer‑supported safety layer.
Synthesis: Choosing the Right Safety Approach for Tower‑Crane Operations
The landscape of tower‑crane safety now spans a spectrum from pure AI analytics to hybrid sensor‑fusion solutions and even wholly physical links. ViAct and Glodon demonstrate how computer‑vision and edge processing can deliver near‑instant hazard detection, accident‑rate reductions, and specialized monitoring such as heat‑stress mitigation. AMCS adds robustness through GNSS‑based geo‑fencing that adapts to the fluid environments of mobile cranes. The Buddie System reminds practitioners that a simple, reliable physical cue can sometimes outperform complex electronics in guaranteeing message integrity. Finally, Potain’s TT3 shows that embedding safety logic at the OEM level can streamline deployment and ensure compatibility across fleets. Selecting the optimal system—or a combination thereof—depends on site‑specific factors such as crane density, environmental conditions, regulatory pressures, and the willingness to invest in either cutting‑edge AI or proven, low‑technology safeguards. By weighing these variables, construction firms can markedly improve crane‑related safety while maintaining productivity and cost‑effectiveness.
https://www.cranebriefing.com/news/crane-safety-systems/8128371.article