Mobile crane inspections

The following information is designed to assist with identification of the inspections and testing required when using a mobile crane on a construction site.

Overview

Oftentimes, mobile cranes represent the most expensive production tool at a project site; yet, contractors often do not require or determine any evidence of its worthiness to perform its function. In order to identify defects that may reflect a potential hazard and subsequently contribute to an accident, you must conduct regular inspections. An inspection can aid in identifying maintenance needs that help to prevent the occurrence of serious deterioration. Generally, the safety and reliability of a crane is directly related to the frequency of inspections and maintenance.

Responsibilities for ensuring cranes are inspected and properly maintained lie with the crane owner, crane user, site supervisor, and the crane operator. Understanding what is expected of each role is an important part of ensuring the crane is inspected and maintained in accordance with the manufacturer’s standards, as well as Occupational Safety and Health Administration (OSHA) and American Society of Mechanical Engineers (ASME) standards. While manufacturers publish guidelines to meet routine maintenance schedules, they may require modification based on the usage of each individual machine. If any part of the manufacturer’s procedures is more stringent than the OSHA requirements, then the manufacturer’s procedures must be followed.

Inspections

The OSHA standards for construction address crane inspections under 29 CFR 1926.1412. Some additional information regarding crane inspections can be found in ASME B30.5, Chapter 2. When a crane comes onto a construction site, the controlling contractor should require evidence of the crane’s last inspection and/or annual inspection.

Initial inspection

ASME B30.5 requires an initial inspection of mobile cranes. The new owner of a crane should conduct an inspection of the unit upon delivery of the unit to their firm. That inspection should include the following:

General (upper and carrier)

• Check condition of unit for any damage during shipping.
• Check oil compartment(s) and lubricants for proper levels.

Engine

• Check all fluid, oil and water levels. Start the engine and check pressures and temperatures.

Brakes

• Check air pressures and low pressure warning alarms.
• Check brake operations.

Clutches

• Verify adjustment of all clutches.
• Inspect clutch for damaged components, alignment, contamination, etc.

Hydraulics

• Inspect for leakage or damage, correct operation pressures, belt tensions and proper fluid levels.

Electrical

• Inspect condition of lighting systems, instrumentation gauges, windshield wipers, horns, etc.

Daily inspections (each shift)

According to OSHA 29 CFR 1926.1412, a competent person must conduct an inspection prior to each shift when the equipment will be used. The inspection must include a visual inspection for apparent deficiencies. Taking apart equipment components and booming down is not required as part of this inspection unless the results of the visual inspection or trial operation indicate that further investigation is needed.

At a minimum, the daily inspection must include all of the following:

• Ensure that the controls are adjusted correctly and do not interfere with proper operation.
• Inspect controls and drive mechanisms for excessive wear and contamination by lubricants, water or other foreign matter.
• Inspect air, hydraulic, and other pressurized lines for deterioration or leakage – especially those that flex during normal operation.
• Check the hydraulic system for proper fluid level.
• Inspect hooks and latches for deformation, cracks, excessive wear or damage from chemicals or heat.
• Inspect wire rope reeving for compliance with the manufacturer’s specifications.
• Visual inspection of the wire rope, including running and standing. Items to inspect include significant distortion of the rope structure, kinking, crushing, birdcaging, unstranding, signs of core failure, broken wires, significant corrosion, and heat damage. The end connections should also be inspected for proper application.
• Inspect electrical components for proper functioning. Look for signs of excessive deterioration, dirt or moisture accumulation.
• Inspect tires (when in use) for proper inflation and condition.
• Ensure ground conditions around the equipment provide proper support. Look for settling ground under and around outriggers/stabilizers/tires/tracks and blocking.
• The crane should be in a level position; within the tolerances specified by the crane manufacturer’s recommendations. Level condition should be verified both before each shift and after each move and setup.
• The operator cab windows should be free of significant cracks, breaks or other deficiencies that would hamper the operator’s view.
• Inspect safety devices and operator aids for proper operation.

If any deficiency is identified, an immediate determination must be made by the competent person as to whether the deficiency constitutes a safety hazard. If the deficiency is determined to constitute a safety hazard, the crane must be taken out of service until it has been corrected.

When the crane has been taken out of service (or a function has been taken out of service), a tag must be placed in the cab stating that the equipment is out of service and is not to be used. Although not required by OSHA, it is recommended that daily inspections be documented. Someone should periodically review the crane inspection documentation to ensure that it is accurate.

Monthly inspections

According to OSHA 29 CFR 1926.1412, monthly inspections must be conducted by a competent person. These inspections are intended to identify the need for repair or replacement of parts. A monthly inspection includes the same items as what is required to be inspected as part of the shift inspection. The name and signature of the person who conducted the inspection, the date or the inspection, the items checked and the results of the inspection must be documented. According to OSHA 29 CFR 1926.1412(e), documentation of this inspection must be kept for a minimum of three months.

Annual inspections

According to OSHA, the crane must be inspected by a qualified person annually. Disassembly is required, as necessary, to complete this inspection. The inspection must include functional testing to determine that the crane is configured and is functioning properly. Additionally, all manufacturers’ procedures and inspection criteria must be followed.

At a minimum, the following information should be included in the annual inspection:

• Structural members (including the boom, extension and jib) should be inspected for deformed, cracked, loose fasteners, failed welds and significant corrosion.
• The sheaves and drums should be checked for cracks or significant wear.
• Parts such as pins, bearings, shafts, gears, rollers and locking devices should be inspected for distortion, cracks or significant wear.
• The brake and clutch systems; linings, pawls and ratchets should be inspected for excessive wear.
• Safety devices and operator aids should be checked for proper operation.
• Leaking exhaust should be repaired and emergency shut-down features should be operational.
• Chains and chain drive sprockets should be inspected for excessive wear of sprockets and excessive chain stretch.
• Check for cracked crane hooks.
• The travel, steering, brakes and locking devices should be checked for proper operation.
• Inspect the tires for damage or excessive wear.
• The hydraulic, pneumatic and other pressurized hoses, fittings and tubing should be checked for leaks, blistering, excessive abrasion, deformation or other signs of impending failure.
• The hydraulic and pneumatic pumps, cylinders, valves and motors should be inspected for unusual noises or vibration, low operating speed, leaks, cracks, loss of operating speed, excessive heating of the fluid, low pressure, loose bolts or fasteners, damaged cylinder rods, and dented cases (barrels).
• Hydraulic filters should be checked for rubber particles and metal chips.
• Damaged outrigger or stabilizer pads/floats should be properly addressed.
• Slider pads should be checked for excessive wear or cracks.
• Electrical components and wiring should be free of cracked or split insulation and loose or corroded terminations.
• Replace missing or unreadable warning labels and decals originally supplied with the crane by the manufacturer.
• Originally equipped operator seat (or equivalent) should be in place.
• Originally equipped steps, ladders, handrails and guards should be in place and in safe usable condition.

If any deficiency is identified, an immediate determination must be made by the qualified person as to whether the deficiency constitutes a safety hazard or, though not yet a safety hazard, needs to be monitored in the monthly inspections.

If the qualified person determines that a deficiency is a safety hazard, the equipment must be taken out of service until it has been corrected (except when temporary alternative measures can be implemented).

If the qualified person determines that, though not presently a safety hazard, the deficiency needs to be monitored, the employer must ensure that the deficiency is checked in the monthly inspections.

The name and signature of the person who conducted the inspection, the date or the inspection, the items checked and the results of the inspection must be documented. This documentation must be kept for a minimum of one year.

Other crane inspections

In addition to the above inspections, OSHA requires cranes to be inspected at the following times:

Post asembly

Upon completion of assembly, the crane must be inspected by a qualified person to ensure that it is configured as the manufacturer describes.

Modified cranes

Cranes that have had modifications or additions that affect the safe operation of the equipment (such as safety device or operational aids, critical part of a control system, power plant, braking system, load-sustaining structural components, or load hook) or capacity must be inspected by a qualified person after such modifications/additions have been completed, prior to initial use. The inspection must ensure that the modifications or additions have been done in accordance with the manufacturer’s written approval. The crane should have a function test as well.

Repaired/adjusted equipment

Equipment that has had a repair or an adjustment that relates to safe operation (such as: a repair or adjustment to a safety device, operator aid, or to a critical part of a control system, power plant, braking system, load-sustaining structural components, load hook, or in-use operating mechanism), must be inspected by a qualified person after such a repair or adjustment has been completed, prior to initial use. It must be determined that the repair/adjustment meets manufacturer specifications. The crane should have a function test of the repaired/adjusted parts as well.

Severe service

Where the severity of use or conditions are such that there is a reasonable probability of damage or excessive wear (such as loading that may have exceeded rated capacity, shock loading that may have exceeded rated capacity, or prolonged exposure to a corrosive atmosphere), the employer must stop using the equipment and a qualified person must inspect the equipment for structural damage to determine if the equipment can continue to be used safely.

The annual inspection may need to be done again.

Cranes not in regular use

Cranes that have been idle for 3 months or more must be inspected by a qualified person in accordance with the requirements of the monthly inspections before being put back in use. Cranes idle for more than one year must have an annual inspection before being put in use.

Wire rope inspection

There are also inspection requirements for the wire rope on the crane. These requirements can be found in OSHA 29 CFR 1926.1413 and ASME B30.5.

It is recommended that the crane owner utilize a log book, which identifies the unit by serial number and shows all of the inspections and services provided to the unit. Within the log, all work performed and by whom should be documented, along with information regarding inspection of boom sections and structural elements designed and manufactured by those other than the original manufacturer.

Reference

• Construction Safety Association of Ontario - Crane Handbook
• ASME B30.5 most recent edition
• 29 CFR 1926.1412