Notice

Overhead Crane Safety y and Inspection Requirements

It is the responsibility of the Owner/User to install, inspect, test, maintain, and operate a crane or associated lifting equipment in accordance with the applicable volume of the ANSI/ASME B30 Safety Standard, OSHA Regulations, and ANSI-NFPA 70, National Electric Code and local regulations and laws. If the crane or associated lifting equipments is installed as part of a total lifting system, it is also the responsibility of the owner/user to comply with the applicable ANSI/ASME B30 volumes that address other types of equipment used in the system. Further it is a responsibility of the Owner/User to require all personnel who install Further, install, inspect inspect, test test, maintain, and operate a crane or associated lifting equipment to read and to comply with the contents of the instruction manuals furnished by the manufacturer of the crane or associated lifting equipment, and the applicable portions of the volume of the ANSI/ASME B30 Safety Standard, OSHA Regulations, and the ANSI/NFPA 70, National Electric Code. If the crane or associated lifting equipment is installed as part of a total lifting system, the applicable ANSI/ASME B30 volumes that address other types of equipment used in the systems must also be read and followed by all personnel.

Daily Operator Inspection Requirements

Daily Operator Inspection Reuirements

Tagged Control Brakes Hook Hook Limit Oil

Crane or Hoist Devices

Tagged Crane or Hoist

Check

that the crane or hoist is not tagged with an out out-of-order of order sign sign.

Latch

Reeving

Switches Leakage Unusual Sounds

Daily Operator Inspection Requirements

Daily Operator Inspection Requirements

Control Devices
Check

that all motions agree with control device markings e.g., Up/Down/Fwd/Rev.

Brakes (Travel)
Check

that all motions do not have excessive drift and that stopping distances are normal (approx. 10% of high speed travel. drift permitted.

Hoist Brakes
No

Daily Operator Inspection Requirements

Daily Operator Inspection Requirements

Hook
Check

Hook Latch
Check

for damage, cracks, nicks, gouges, deformity of the throat opening, wear on saddle or load bearing point, and twist. Refer to the manual furnished by the original manufacturer of the crane or hoist.

that hook latch, if p provided, is not missing g and that it operates properly.

Daily Operator Inspection Requirements

Wire Rope Inspection Broken Wires

Wire Rope
Broken Kinks Crushing Stretching Birdcaging Rope Excessive

Wires Wear

10 wires in one rope lay 5 wires in one strand in one rope lay

Measurement

Wire Rope Inspection Excessive Wear

Wire Rope Inspection Kinks

Loss of 1/3 of the rope diameter of individual wires.

Wire Rope Inspection Crushing

Wire Rope Inspection Stretching

Wire Rope Inspection Birdcaging

Wire Rope Inspection How to Measure

The components of a wire rope each have a small but definite size tolerance. Therefore, the rope itself must have a diameter at least equal to the nominal, or catalog, size never smaller.

Wire Rope Inspection

Daily Operator Inspection Requirements

Replace any wire rope or red tag if you observe any of these conditions! diti !

Load Chain
Check

load chain, including end connections for excessive wear, twist, distorted links or stretch, beyond the manufacturers recommendations.

Daily Operator Inspection Requirements

Daily Operator Inspection Requirements

Reeving

Limit Switches

Check that the wire rope or load chain is properly reeved and that rope or load chain parts are not twisted about each other. Make sure wire rope is properly seated in drum grooves.

Check that the upper limit device stops lifting motions of the hoist load block before striking any part of the hoist or crane. crane Caution: exercise extreme care during this test to avoid striking any part of the hoist or trolley with the hoist load block or lift beam in the event of a faulty limit switch.

Daily Operator Inspection Requirements

Daily Operator Inspection Requirements

Oil Leakage
Check

Unusual Sounds
Check

for any sign of oil leakage g on the crane and on the floor area beneath the crane.

for any unusual sounds such as

Squealing q g Grinding Unusual vibration

from

the crane or hoist mechanism while operating the crane and hoist.

Daily Operator Inspection Requirements

Periodic Inspection

Warning and Safety Labels and Warning Devices

Check that warning and other safety labels are not missing and that they are legible. Check that audible and visual warning devices are operational.

A Periodic Inspection is a detailed visual and operational inspection whereby individual components are examined to determine their condition. The Periodic Inspection is performed as often as quarterly based on service, environmental and application factors as determined by a qualified person or as outline in the following table.

Periodic Inspection Chart

(as required by OSHA)
Number of Shifts Operated per Day ASME B30 B30.2 2 Service Class

Periodic Inspection Items Required by OSHA

A. B. C. D. E. F. G. H. I. J. K. L. M. N. O. P.

1 Shift

2 Shifts Frequency of Inspection

3 Shifts

Normal Heavy Severe

ANNUAL ANNUAL QUARTERLY

ANNUAL QUARTERLY

ANNUAL QUARTERLY

SEMI-ANNUAL TO ANNUAL SEMI-ANNUAL

Structural Members Signs and Labels Connection Points Sheaves and Drums Shafts, Axles, Wheels, Couplings Brakes ( (holding g and control) ) Indicators, Gauges Self-contained Electric, Hydraulic, or Gasoline Powered Generating Units Transmissions Electrical Components Covers and Guards Bumpers and End Stops Trolley and Runway Rail Runway Structure Conductor System Below-the-Hook Devices

Periodic Inspection Items Required by OSHA

A. Structural members, such as girders, end trucks, footwalks, trap doors, ladders, handrails, trolley frame cab frame, cab, etc etc.
Check for deformed, cracked, corroded or unsecured members. Are foot walks free of debris, grease, etc.? Does cab have a fire extinguisher, proper type?

Periodic Inspection Items Required by OSHA

B. Signs and Labels
Check for proper capacity labels. Are they legible from the floor? Are warning signs in place and legible? Was cranes test loaded? Did you record in your records?

Periodic Inspection Items Required by OSHA

C.

Periodic Inspection Items Required by OSHA

D.

Connection Points

Sheaves and Drums

Check for loose/broken bolts or rivets Check for rivets. cracked or insufficient welds.

Check for worn grooves, worn g g groove lands, sharp edges, and cracks.

Periodic Inspection Items Required by OSHA

E.

Periodic Inspection Items Required by OSHA

F.

Shafts, Axles, Wheels, Couplings

Brakes (Holding and Control)

Check for worn, worn cracked bent or broken parts. Check for loose/missing hardware.

Check for excessive wear and proper adjustment on brake system parts, linings, pawls and ratchets. Check for proper functioning of electric control brake.

Periodic Inspection Items Required by OSHA

G.

Periodic Inspection Items Required by OSHA

H.

Indicators, Gauges or Other Devices

Transmissions

Check for load, wind, and other indicators over their full range, re-calibrate as required.

Check for excessive wear of chain drive sprockets and excessive chain stretch. Open gearbox inspection covers and check for gear teeth wear and proper lubrication.

Periodic Inspection Items Required by OSHA

Electrical Components

Periodic Inspection Items Required by OSHA

Electrical Components
Controller Limit

Check all electrical apparatus for signs of pitting or any deterioration of controller contactors, limit switches, pushbutton stations, motor slip rings, brushes, resistors. Check for any loose wire connections for damaged wiring. Check for evidence of overheating. Make sure door or cover closed properly.

contactors switches Push button stations

Periodic Inspection Items Required by OSHA

Periodic Inspection Items Required by OSHA

J.

Electrical Components
Motor

Covers and Guards

slip rings Brushes Resistors

Check that all covers or guards are in p g place, secure, and undamaged.

Periodic Inspection Items Required by OSHA

K.

Periodic Inspection Items Required by OSHA

L.

Bumpers and End Stops

Trolley and Runway Rail

Check all bumpers and end d stops f for d damage. Check for proper restraints and obvious under sizing or improper energy absorption capabilities.

Check rails and f t i devices fastening d i f for looseness, gaps, misalignment, wear.

Periodic Inspection Items Required by OSHA

L.

Periodic Inspection Items Required by OSHA

M.

Trolley and Runway Rail

Runway Structures

Check runway structure for proper anchors loose bolted anchors, connections, corrosion, cracked or deformed members.

Periodic Inspection Items Required by OSHA

N.

Periodic Inspection Items Required by OSHA

O.

Conductor System

Check the conductor systems for:

Below-the-Hook Devices

Alignment Fastening Splices Power feeds Conductor shoes for wear.

Check for cracks or structural damage. Check mechanical components for wear wear, alignment, and missing/loose hardware. Check all motors, controls, wiring. Check that all guards are in place and secure.

For details, see below-the-hook presentation

Operational Safety Before Lifting

Operational Safety Before Lifting

Lifters must only be used by trained operators. Do not allow yourself to be distracted. Pay y attention to what you are doing. Test operation of moving lifter parts and controls at the beginning of each shift.

Do not overload crane or hoist. Make sure the combined weight of the lifter and load does not exceed the rated load capacity of the crane or hoist. Refuse to make lift if you are unsure of any issues. Do not proceed until all issues are resolved.

Illustration

Operational Safety Before Lifting

Operational Safety Before Lifting

To ensure load is balanced and stable, make a preliminary lift of a few inches. Do not overload lifter. Do not try to lift a load that is too big for the lifter. Do not pick up hot loads unless the lifter is specially designed for high temperature service.

Make sure hoist rope or chain is free from twists, knots and kinks. Multiple part lines should not be twisted around each other.

Operational Safety Moving a Load

Operational Safety Moving a Load

Take instructions only from the person designated to give signals. Do not ride or allow other people to do so. Do not lift load higher than necessary to avoid obstructions in its path.

Do not allow loads to come in contact with other objects. Make sure the path of travel is free of obstructions before moving the load. Do not lift loads over p people. p Stay y out from under the load and make sure other people remain at a distance. Avoid sudden starts and stops. This prevents shock loading which can stress the system beyond its capacity.

Operational Safety Moving a Load

Operational Safety Moving a Load

Stay clear while moving load. Do not allow load to swing. Use a rod to push load or a tag line to pull the load. Exercise particular caution with p load sheet lifters. Be sure to keep level. Tilting the lifter could cause the load to slide off the lifter. Always lower load to ground and check its stability before leaving the area.

Make sure the lifter is properly stored after use. Lifters are big and heavy and can cause personal injury or property damage if they fail. Some lifter require a specially designed stand. Others may be stored on a level surface.

Crane Inspector Definition

Any

Crane Inspector Work Experience

person engaging in the testing, examination and/or certification of cranes, including but no limited to top running and under-running bridge and gantry type, single or girder overhead traveling g double g cranes and associated hoisting equipment.

Shall have a minimum of 2,000 field hours of experience related to maintaining, servicing, repairing, modifying and functional testing of cranes and associated hoisting equipment. Experience should provide a working knowledge of how to identify deficiencies in mechanical, structural, electrical systems and components of cranes.

Crane Inspector Physical Qualifications

Crane Inspector Physical Qualifications

Vision of at least 20/30 in one eye and 20/50 in the other with or without correction. Normal depth perception, field of vision, hand-eye coordination, and no tendencies to dizziness or similar conditions conditions. Not have evidence of physical restrictions; not be subject to seizures or loss of physical control, or emotional instability that could render a hazard to the technician or others.

Be able to hear, with or without hearing aid, adequately for a specific task. Have sufficient strength, endurance agility, coordination, manual dexterity and speed of reaction to meet the demands of the job. job Be capable of working at extended heights in a safe manner under varying environmental and adverse physical conditions.

Crane Inspector Other Qualifications

Crane Inspector Required Training

Should demonstrate proficiency to read and write in English. Should demonstrate proficient oral and written communication skills. Should be subject to other safety, drug or other specific Seller and/or Purchasers requirements. Should be able to distinguish colors, if color differentiation is required for the task.

Should have received formal training in the areas of: safety and design codes related to cranes: Federal, State and local codes and regulations; safe operating practices of cranes; report writing and documentation; and communication skills. An inspector should receive additional formal training every two years as a minimum and be able to provide documentation of such training.

Crane Inspector Required Training

Additional

Crane Inspector Required Training

Testing Inspector shall be required to demonstrate proficiency by passing both a written and practical examination. Inspector should be able to present documentation of successful completion of above qualifications. Certification/Licensing If local code bodies or governments mandate, additional testing and registration for inspector certification or licensing may be required.

training should include, but not be limited to the following areas:

Trade skills Products Safety Tolls & Equipment Job-site Conduct

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Recommended Forms OSHA Crane Inspection Report

Recommended Forms Maintenance Log

Maintenance

Log OSHA Crane Inspection Report Trouble Shooting Guide

Click on picture to open .pdf df file. fil

Recommended Forms OSHA Crane Inspection Report

Recommended Forms OSHA Crane Inspection Report Alternate Version

Click on picture to open .pdf df file. fil

Click on picture to open .pdf df file. fil

Recommended Forms Trouble Shooting Guide

Standard Hand Signals

Click on picture to open .pdf df file. fil

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Standard Hand Signals

Standard Hand Signals

Standard Hand Signals

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