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The proper operation and safety of your overhead cranes and hoists is vitally important since they potentially carry heavy loads near workers and over critical machinery and equipment. In addition, your overhead cranes and hoists most likely are critically important parts of your manufacturing and material handling process. Unplanned downtime caused by breakdowns could bring your production process to a halt. The operational failure of an overhead crane or hoist could shut down your production, or worse, injure a worker. Therefore, proper inspections, repairs and preventive maintenance of your cranes and hoists are not only the “law” (mandated by OSHA and ANSI), but really make smart business sense! An operational overhead crane helps keep your business running, while a failed crane can shut it down.

Safety Inspection Requirements

Overhead crane and hoists inspections are mandated by both OSHA and ANSI with the various requirements outlined in Federal OSHA 1910.179 regulations as well as various ANSI B30 standards. The types of inspections required in OSHA and ANSI are fairly consistent within the regulation and standards books and include: initial inspection, periodic inspection, frequent inspection, and daily/shift.

“Initial” Inspections: includes a load test of up to 125% of rated capacity and thorough hands-on inspection and operational check of the crane or hoist equipment. The Initial Inspection must be performed when the equipment is installed and whenever repairs are made to critical load-bearing components. The Initial documentation must be maintained for the life of the equipment along with the repair history.
“Periodic” Inspections: include an operational check and thorough hands-on inspection of the crane or hoist equipment. The Periodic Inspection must be performed as frequent as monthly on equipment that has usage that would create the potential for frequent repair and safety issues to as little as annually on seldom-used equipment that has little to no potential for repair and safety issues. The majority of equipment will require quarterly to monthly periodic inspections due to manufacturer requirements and frequency of found defects. Periodic documentation must be also be maintained for the life of the equipment.
“Frequent” Inspections: Include an operation check as well as a visual inspection of critical items listed in the codes and standards such as limit switches, wire rope, chain, hooks, etc. Frequent inspections are required at least monthly and generally done in months when the periodic inspections will not be performed.

Typical Inspection Program for Normal Operation 1 Shift Per Day

Jan	Feb	Mar	Apr	May	Jun	Jul	Aug	Sep	Oct	Nov	Dec
Periodic & Frequent Inspection	X	X	X	X
Frequent Inspection	X	X	X	X	X	X	X	X

Typical Inspection Program for Heavy Operation 1 Shift Per Day

Jan	Feb	Mar	Apr	May	Jun	Jul	Aug	Sep	Oct	Nov	Dec
Periodic & Frequent Inspection	X	Format edittext android. X	X	X	X	X
Frequent Inspection	X	X	X	X	X	X

Typical Inspection Program for Heavy Operation Multiple Shift Per Day

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Periodic & Frequent Inspection

Frequent Inspection

Correction of Safety and Repair Deficiencies

After an inspection of the overhead crane and hoist, the responsibility to ensure that any found safety and repair deficiencies are properly corrected falls back on the “designated individual”. The “designated individual” in this case is an OSHA term for the person assigned the task of reviewing the inspection program as well as the resultant reports and ordering repairs. The important part to remember here is that all repairs that constitute a safety hazard must be corrected prior to the equipment being placed back in service. So if you continue to operate cranes or hoists with known safety hazards, you are placing your workers’ safety and organization at great risk.

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Qualified Inspectors

Whom you allow to inspect your cranes is as just as important as the proper frequency of inspection. The controls that operate the motors and brakes as well as the complex safety limits, specifically designed to protect life and property, are truly unique to crane and hoisting equipment. Making matters worse, mechanical and control designs can vary greatly from one brand to the next. Therefore to ensure safety, crane equipment must only be inspected and repaired by skilled and experie

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