The Ultimate Guide to
Safety Matters
Safety Matters
Safety Matters
Safety Matters
Safety Matters
Regular Maintenance
Regular Maintenance
Regular Maintenance
Regular Maintenance
Regular Maintenance
It’s easy to forget about routine maintenance & inspections when production runs smoothly. Yet, when it comes to crane & hoist rigs 
reduced production time & costly repairs caused by malfunctions are the best case scenarios. Failure, oversight, & mistakes can be catastrophic. This is why the building & operation of heavy lift equipment is highly regulated. Not adhering to strict inspection schedules & proper repair may result in hefty fines, serious injury, & even death.
But when should these critical steps be done & who should perform them varies greatly. So, as a leader in the industry, we’ve put together a complete guide to the different types of inspections when, & how the must be completed.
Navigate the Ultimate Guide or Continue Reading Below
You can find a full list of our citations here.
Main Inspection Types
The Occupational Safety and Health Administration (OSHA) & American National Standards Institute (ANSI) regulate and interpret the standards for crane & hoist machinery. Overhead and gantry crane general requirements, design, inspection, maintenance requirements and operations are covered by OSHA’s 29 Code of Federal Regulations (CFR) 1910.179 which defines 3 types of inspections: initial inspections, frequent inspections, & periodic inspections.
Performed By: Qualified Person
Initial Inspection
Required after installing a new crane or hoist, and for equipment that has been reinstalled after alteration, modification or repair. Any deficiencies that need to be watched MUST be documented.
Performed By: Competent Person
Frequent Inspection
Required in daily to monthly intervals but are not required to be documented. Monthly inspections must be signed by the person who conducted the inspection and retained for a minimum of 3 months.
Performed By: Competent Person
Periodic Inspection
Required in one to twelve month intervals. Required. Must be signed by the person who conducted the inspection and retained for a minimum of 12 months.
Initial inspections insure compliance of all new and altered cranes before initial use. This inspection must be performed by qualified person to determine if the repair/adjustment meets manufacturer equipment criteria.
When Needed
Description
What's Inspected
New Equipment
Required after installing a new crane or hoist, and for equipment that has been reinstalled after alteration
The entire equipment piece must be approved by a certified professional.
Modified Equipment
Equipment that has had modifications or additions which affect the safe operation of the equipment .
Any such modification or addition must be approved by either the manufacturer or a registered professional engineer.
Repaired/Adjusted Equipment
Equipment that has had modifications or additions which affect the safe operation of the equipment .
Any such modification or addition must be approved by either the manufacturer or a registered professional engineer.
Frequent inspections are not as comprehensive as initial inspections, but just as critical. These look for defaults in equipment at defined daily & monthly intervals, including examination for issues during use that appear in regular inspections. Any defects must be examined & determined as to whether or not they constitute a safety hazard.
Click to enlarge.
When Needed
Description
What's Inspected
Shift Inspections
At the start or end of each shift. Depending on equipment type & use-case.
See below for minimum parts needing inspection.
Monthly Inspections
Regular, scheduled inspections that occur every month. More comprehensive than shift inspections.
See below for minimum parts needing inspection.
Equipment Inspected
- Control mechanisms for maladjustments interfering with proper operation.
- Control and drive mechanisms for apparent excessive wear of components and contamination by lubricants, water or other foreign matter.
- Air, hydraulic, and other pressurized lines for deterioration or leakage, particularly those which flex in normal operation.
- Hydraulic system for proper fluid level.
- Hooks and latches for deformation, cracks, excessive wear, or damage such as from chemicals or heat.
- Wire rope reeving for compliance with the manufacturer’s specifications.
- Wire rope
- Electrical apparatus for malfunctioning, signs of apparent excessive deterioration, or dirt or moisture accumulation.
- Tires (when in use) for proper inflation and condition.
- Ground conditions around the equipment for proper support, including ground settling under and around outriggers/stabilizers and supporting foundations, ground water accumulation, or similar conditions.
- The equipment for level position within the tolerances specified by the equipment manufacturer’s recommendations, both before each shift and after each move and setup.
- Operator cab windows for significant cracks, breaks, or other deficiencies that would hamper the operator’s view.
- Rails, rail stops, rail clamps and supporting surfaces when the equipment travels on rails.
- Safety devices and operational aids for proper operation.
- Deficiencies identified during the most recent annual inspection that the inspector determined must be monitored in the monthly inspections.
Periodic inspections are complete inspections of the crane that should be performed at intervals depending on its activity, severity of service, environment, or otherwise specifically stated by manufacturers. The annual inspection is much more thorough than a frequent inspection and must be conducted by a qualified person. In addition to those items that must be checked during a shift inspection, the annual inspection must include:
Hydraulics & Pneumatics
Any pressurized elements such as motors, casing, hoses, fittings, or tubing.
Safety & Stability Elements
These include things such as stabilizer pads, steps, rails, labels, & signage.
Differences in Frequent & Periodic Inspections
- If necessary, disassembly is required to complete the annual inspection
- Inspection must include functional testing to determine that the equipment as configured in the inspection is functioning properly.
- Inspection results must be documented, maintained, and retained for a minimum of 12 months, by the employer that conducts the inspection including: the items checked and the results of the inspection, the name and signature of the person who conducted the inspection, and the date.
Inspection
Frequency/Description
What's Inspected
Documentation
Not in Regular Use 3 months
Equipment that has been idle for less than 6 months.
Inspected in accord with the requirements for monthly inspections.
Requirements in accordance with monthly inspections.
Not in Regular Use 6 months
Equipment that has been idle for more than 6 months.
Inspected in accord with the requirements for monthly & annual inspections.
Requirements in accordance with monthly & annual inspections.
Severe Service
Where the severity of use/conditions is such that there is a reasonable probability of damage or excessive wear.
Inspect the equipment for structural damage and any items/conditions that must be inspected during an annual inspection need to be inspected.
Depending on the results of the inspection.
When Issues Arise
- First, it’s extremely important to have an action plan for ̶i̶f̶ when issues arise, big or small.
- Have physical copies close to the work area, that anyone on the crew can deploy. Make sure the entire team is aware of it.
- If a component is damaged to the extent that it would create a safety hazard, that component must be repaired. If it’s determined that a component needs to be monitored, the component is checked in the monthly inspections.
- For the other items covered by the inspection, if the inspector finds any deficiency in an item, he/she must determine if the deficiency is serious enough to be a safety hazard. If so, the equipment must not be used until the deficiency is corrected. Shift inspections need not be documented.
- Have contact information for local emergency services, & your equipment service/repair provider.
Important Reminder
Make sure to check equipment manuals & manufacturer guidelines for important safety standards & other inspection requirements.
Why Choose Zeller Technologies
We provide on-point inspections & testing. Periodic & regular inspections are performed by our pro team in accordance with current OSHA / ANSI standards. Aside from these regulations, our process also exposes other potential or problematic results that will lead to costly breakdowns or more serious issues.
We provide on-point inspections & testing. Periodic & regular inspections are performed by our pro team in accordance with current OSHA / ANSI standards. Aside from these regulations, our process also exposes other potential or problematic results that will lead to costly breakdowns or more serious issues.
Inspection Equipment Types
Structural Equipment
- Equipment structure (including the boom and, if equipped, the jib).
- Structural members: deformed, cracked, or significantly corroded.
- Bolts, rivets and other fasteners: loose, failed, or significantly corroded.
- Welds for cracks.
- Sheaves and drums for cracks or significant wear.
- Parts such as pins, bearings, shafts, gears, rollers and locking devices for distortion, cracks, or significant wear.
- Brake and clutch system parts, linings, pawls, and ratchets for excessive wear.
- Safety devices and operational aids for proper operation (including significant inaccuracies).
- Gasoline, diesel, electric, or other power plants for safety-related problems (such as leaking exhaust and emergency shutdown feature) and conditions, and proper operation.
- Chains and chain drive sprockets for excessive wear of sprockets and excessive chain stretch.
- Travel steering, brakes, and locking devices, for proper operation.
- Tires for damage or excessive wear.
Hydraulics & Pneumatics
- Hydraulic, pneumatic and other pressurized hoses, fittings, and tubing.
- Flexible hose or its junction with the fittings for indications of leaks.
- Threaded or clamped joints for leaks.
- Outer covering of the hose for blistering, abnormal deformation, or other signs of failure/impending failure.
- Outer surface of a hose, rigid tube, or fitting for indications of excessive abrasion or scrubbing.
- Hydraulic and pneumatic pumps and motors, as follows:
- Performance indicators: unusual noises or vibration, low operating speed, excessive heating of the fluid, low pressure.
- Loose bolts or fasteners.
- Shaft seals and joints between pump sections for leaks.
- Hydraulic and pneumatic valves, as follows:
- Spools: sticking, improper return to neutral, and leaks.
- General Leaks.
- Valve housing cracks.
- Relief valves: failure to reach correct pressure (if there is a manufacturer procedure for checking pressure, it must be followed).
- Hydraulic and pneumatic cylinders, as follows:
- Drifting caused by fluid leaking across the piston.
- Rod seals and welded joints for leaks.
- Cylinder rods for scores, nicks, or dents.
- Case (barrel) for significant dents.
- Rod eyes and connecting joints: loose or de- formed.
Safety & Stability Elements
- Outrigger or stabilizer pads/floats for excessive wear or cracks.
- Slider pads for excessive wear or cracks.
- Electrical components and wiring for cracked or split insulation and loose or corroded terminations.
- Warning labels and decals originally supplied with the equipment by the manufacturer or otherwise required under this standard: missing or unread- able.
- Originally equipped operator seat (or equivalent): missing.
- Operator seat: unserviceable.
- Originally equipped steps, ladders, handrails, or guards: missing.
- Steps, ladders, handrails, or guards: in unusable/unsafe condition.
- For derricks, gudgeon pins for cracks, wear, and distortion, and foundation supports for continued ability to sustain the imposed loads).
Operator Training Classes
The goal of our Operator Training Classes, held at your facility or ours, is to provide a safe work environment to minimize the probability of injury & reduce insurance costs.
Instructed by one of our OSHA Certified techs, it covers proper usage of a hoist/crane, the do’s and dont’s, as well as safe rigging. Class materials & on-site reference documents are provided. Ensure safety to your operation & the welfare of your crew.
Additional Resources
According to OSHA, “State Plans are OSHA-approved workplace safety and health programs operated by individual states or U.S. territories. There are currently 22 State Plans covering both private sector and state and local government workers, and there are six State Plans covering only state and local government workers. State Plans are monitored by OSHA and must be at least as effective as OSHA in protecting workers and in preventing work-related injuries, illnesses and deaths.”
Crane & Hoist Contact
Crane & Hoist Contact
Mike Stearns – Inspections & Service
314.638.9641 x.229
mstearns@
For Parts Only:
craneparts@
Repair: Ship To
4250 Hoffmeister Ave
St. Louis, MO 63125
Competencies
- New Cranes
- Hoist & Crane Repair
- Control Upgrades
- Radio Upgrades
- Inspections
- Load Testing
- Tests & Maintenance
- Certification Classes
Service Areas
- Missouri
- Illinois
- Iowa
- Indiana
- Arkansas
- Kansas
- Kentucky
- Tennessee