Overhead crane inspections: frequent and periodic

Overhead cranes are inspected at several levels. The operator checks the crane before each use, a designated person carries out frequent inspections of working parts, and a qualified inspector carries out periodic inspections that look more deeply at the structure and components. Each level catches different problems, and together they keep cranes safe between major services.

Standards and regulations

In Canada, CSA B167 covers the design, inspection, testing, maintenance and safe operation of overhead travelling cranes, gantry cranes, monorails and hoists. It uses the familiar division between frequent and periodic inspections, which is also used in the ASME B30 series of standards. Provincial occupational health and safety rules, including the Alberta OHS Code and the regulations in BC and Ontario, require cranes to be inspected and maintained, often by reference to CSA B167 or the manufacturer's instructions, and set requirements for records and operator competency. Some provinces also have specific certification or registration rules for certain cranes. Check the current edition of B167 and the rules in your province.

Inspection intervals in the standards depend on how hard the crane works. A crane in heavy service, such as a production crane running most of a shift, needs closer attention than a maintenance crane used a few times a month.

Pre-use checks by the operator

Before using the crane, usually at the start of each shift, the operator does a quick visual and functional check. This is not a formal inspection, but it catches many obvious problems:

• Area clear, and the runway and travel path free of obstructions
• Controls and pendant labelled, undamaged and working in the right directions
• Emergency stop and mainline disconnect working
• Upper limit switch stopping the hook block, tested with no load and with care
• Hook undamaged, latch working, no twisting or opening
• Wire rope or chain free of obvious kinks, broken wires or damage, and spooling correctly
• Brakes holding without drift
• No unusual noise, vibration or smell during operation
• Warning devices and lights working

Any defect affecting safety means the crane is tagged out of service and reported until a competent person has assessed it.

Frequent inspections

Frequent inspections are carried out at intervals that range from daily to monthly, depending on service. A designated, trained person looks at the working parts that wear quickly or affect safe operation. Typical items include:

• Operating mechanisms, for proper function and adjustment
• Limit switches, including hoist upper limits and travel limits
• Hooks and latches, for deformation, cracks and wear
• Hoist ropes or load chain, and their end connections
• Reeving, to confirm the rope is correctly routed
• Brakes for hoist, trolley and bridge
• Air or hydraulic systems, where present, for leaks and pressure
• Pendant controls and cables

Frequent inspections are usually visual and functional. They may not require disassembly, but the inspector needs to get close enough to see what they are checking.

Periodic inspections

Periodic inspections happen at longer intervals, commonly from monthly to annually depending on service, and are done by a qualified inspector with the crane locked out where needed. They include everything in the frequent inspection plus a closer look at the structure and components:

• Structural members for deformation, cracks and corrosion
• Bolts, rivets and welds for looseness and cracking
• Sheaves and drums for wear and cracks
• Bearings, gears, shafts and couplings for wear
• Brake linings and other brake parts for wear
• Wheels, rails, end stops and bumpers
• Electrical equipment: collectors, conductor bars, controllers, motors and wiring
• Load indicators and overload devices, where fitted
• Capacity markings, visible from the operating position
• Runway alignment and supports, as part of the overall system

Other inspections and tests

• Initial inspection and load test before a new, relocated or altered crane goes into service.
• Load tests after repairs to load-bearing parts, as required by the standard and a qualified person.
• Inspection of cranes not in regular use before they return to service after being idle.
• Inspections after an event such as an overload, collision, fire or seismic event.

Records

Keep written records of frequent and periodic inspections, repairs, load tests and rope replacements for each crane, and make them available to workers, operators and inspectors. Records should show the date, who did the work, what was found and how it was fixed. Many provinces require crane logbooks. Rigging gear used with the crane needs its own inspection; see rigging and sling inspection, and for planning lifts, lift plans and rigging safety.

How ehZee can help

Our crane inspections look at the condition of overhead cranes, hoists and runways, and at inspection and maintenance records against the schedule that applies. Where your province requires a specific certified inspection, we can help you prepare for it, follow up on findings and coordinate repairs with qualified crane contractors.

Common questions