Detailed Inspection Procedures
Follow these step-by-step procedures for key inspection areas on your crane to ensure thoroughness and compliance during inspection operations.
- Ensure crane is parked on level ground and secured
- Engage all brakes and apply wheel chocks if applicable
- Lock out and tag out all power sources
- Verify all required inspection tools are available
- Check weather conditions are suitable for inspection
- Ensure adequate lighting for inspection areas
- Place warning signs and barricade inspection area
- Verify qualified inspector credentials and certifications
- Ensure all required PPE is worn by inspection team
- Review crane documentation and previous inspection records
- Examine main structural members for deformation or cracks
- Inspect all bolted and riveted connections for integrity
- Check welded connections for cracks or deterioration
- Verify bridge structure condition for overhead cranes
- Inspect boom/jib structure for mobile and tower cranes
- Check outriggers and stabilizers on mobile cranes
- Ensure counterweights are secure and properly installed
- Examine trolley and end trucks on overhead cranes
- Assess corrosion levels and paint damage throughout
- Document all structural findings with photographs
- Clean wire rope surface of dirt and lubricant for inspection
- Count broken wires (6 randomly distributed or 3 in one strand)
- Measure rope diameter reduction (reject if more than 5%)
- Check for kinking, crushing, bird-caging, or heat damage
- Inspect chain for excessive wear, stretch, or deformation
- Verify proper lubrication of ropes and chains
- Examine end attachments and connections for security
- Check sheaves and drum condition for excessive wear
- Verify proper rope/chain reeving installation
- Inspect for signs of heat damage or chemical exposure
- Measure hook throat opening for deformation limits
- Perform dye penetrant or magnetic particle crack testing
- Check for hook twist or bending (max 10° from plane)
- Test safety latch engagement and operation
- Verify hook swivel and bearing components function
- Test load moment indicator/limiter operation
- Check anti-two-block device functionality
- Test all limit switches (upper, lower, and travel)
- Verify audible warning devices operation
- Test emergency stop function and response time
- Test hoist motor condition and smooth operation
- Check trolley motor function and performance
- Listen for excessive noise or vibration in gearboxes
- Verify bearing condition and proper lubrication
- Test braking systems (hoist, trolley, and bridge)
- Conduct brake holding capacity test with rated load
- Check for brake drift over 5-minute hold period
- Inspect trolley wheels/rollers for wear and alignment
- Examine hoist drum condition and groove patterns
- Check for oil leaks from gearboxes or hydraulic systems
- Complete all inspection documentation thoroughly
- Photograph any defects or areas of concern
- Document all measurements and test results
- Record inspector certification and signature
- Note any items requiring immediate attention
- Schedule next inspection date and type
- Remove all lockout/tagout devices safely
- Remove inspection area barricades and signage
- File inspection report in crane maintenance records
- Notify operations of crane status and any restrictions
Inspection Pro Tips
- Always use qualified personnel with proper crane inspection training and certifications
- Follow manufacturer-specific inspection requirements in addition to regulatory standards
- Consider weather conditions that may affect both inspection activities and component visibility
- Maintain comprehensive documentation with detailed notes and photographs for compliance
Conclusion
Implementing this comprehensive Crane Inspection Procedure is essential for ensuring safe lifting operations, regulatory compliance, and equipment reliability. By systematically following these procedures according to established schedules, safety personnel can identify potential issues before they lead to catastrophic failures or accidents. Regular crane inspections not only protect workers and property but also optimize crane performance, extend equipment lifespan, and reduce costly downtime.
For optimal inspection management, consider implementing the HVI APP (Heavy Vehicle Inspection and Maintenance software) to streamline your crane inspection program. While primarily designed for heavy vehicles, the HVI platform is equally effective for managing lift equipment inspections. The system allows digital documentation of inspections, provides real-time alerts for maintenance requirements, and creates comprehensive historical records for each crane. With the Heavy Vehicle Inspection and Maintenance software, managers can easily track compliance, monitor inspection patterns, and ensure all lifting equipment is properly maintained according to regulatory requirements.
Make crane inspections an integral part of your safety management system with the HVI software's comprehensive inspection management solution. Whether for regulatory compliance, risk management, or operational reliability, this digital approach significantly improves inspection thoroughness and documentation while reducing administrative burden on inspectors and safety personnel.