How often
should you inspect your overhead crane? I can tell you that this question gets
asked to me quite often. Depending on the use of the crane, the class, or the location of
the overhead crane, will change the answer to that question quite a bit.
Here, I will give you the guidelines and you can decide which category your
crane falls into.
To know the
frequency of inspection will require you to understand the usage of your
crane. The inspection intervals are
broken up in three usage categories. You have Normal Usage, Heavy Usage, and
Severe Usage. Most overhead cranes fall under normal usage but let me give you
the guidelines for each usage so you can decide for yourself which category
your cranes fall under.
Normal Service – Around 5 lifts an hour, Can pick
up over 50% capacity but not over 50% of loads at rated capacity
Heavy Service – Pick up over 50% of rated
capacity, 5 to 10 lifts an hour and 65% of loads at rated capacity
Severe Service –Pick up near capacity on most
loads, 20+ lifts an hour
According to
ANSI B30.2-2011 there are five categories for overhead crane inspections;
Initial, Functional, Test, Frequent, Periodic, and “Crane not in regular
service”. All these inspections require
a qualified person to determine which deficiencies are safety issues.
Initial Inspection
The initial
inspection is a documented visual inspection that is required after the installation
of a new crane or hoist, and equipment that has been reinstalled from
alteration, modified or repaired.
Functional Test
Inspection
This is your
pre-shift inspection. Every shift your overhead crane operates, this test must
be performed. You will be testing all
the functions of the overhead crane and performing a visual and audible
inspection. In addition to the functional test, the upper limit of the hoist is
also required to be tested, and the wire rope or load chain requires a
visual inspection as well. Documenting this
inspection is not required but it is advised. Documentation will show that the
overhead crane has been tested so other operators on that shift know it is safe
to use. The documentation will also show that you are pro-active when it comes
to safety in your facility which will help greatly if an accident ever does
occur within your facility.
Frequent Inspection
A frequent inspection is another visual and audible inspection of your overhead crane. The frequent inspection is based upon the usage of your crane. There are three different categories of the frequent inspection. Which one does your crane fall into?
Normal
Service – Monthly
Heavy
Service – Weekly to Monthly
Severe
Service – Daily to Weekly
During
this inspection you would do everything on the functional test inspection, and
you also check the “operating mechanisms”. The hoist brake is the most
important component to inspect next to the wire rope or load chain. This will
have to be checked and made sure that it functions properly and any adjustments
would need to be made at this time. The inspector should be listening for any
abnormal sounds. The hook and latch requires an inspection as well. The
frequent inspection does not require a record like the functional test
inspection but “should” be made.
Periodic
Inspection
The
periodic inspection is the inspection that many overhead crane owners call
their annual inspection. The usage of the crane again depends on the frequency
of inspection.
Normal
Service – Yearly
Heavy
Service – Yearly
Severe
Service – Quarterly
Please
note however the periodic inspection is not in the state of California. In
California annual inspections are required on all overhead cranes, and also
quarterly preventive maintenance is required regardless of the service class or
crane capacities.
Now
what about that crane you have that you rarely use? If you have a crane that
has not been used for more than a month but it is under 1 year, then you will
be required to perform an inspection on it prior to use. The same applies if it
has been more than one year as well. My suggestion to you is that if you know
you’re going to use it, then get it inspected. If you know you are not going to
use it, and it will not be used in any emergency then wait to get it inspected
when you need it.
In addition
to the five categories of inspections, the manufacturer of your overhead
crane will sometimes require additional inspections. If this is the case on your overhead crane, then this must be followed as well.
These additional inspections could include quadrennial gear case, motor
coupling, bottom block, or load brake inspections. Your owner’s manual will
list these requirements so make sure you have a copy of one.
There are
several overhead crane owners that I know of that simply either cannot afford
to do the required frequency of inspection or feel that they can get away with
just an annual inspection. However, just doing an annual inspection does not
make you compliant and if the reason you’re doing the annual inspection is to
stay compliant, then you would need to do all the required inspections. A crane
that is used often can be unsafe to use if the frequency of inspection is not
followed. If someone was to get hurt in your facility from a faulty overhead
crane component and OSHA was to investigate, doing one annual inspection is not
going to reduce any penalties. You still missed the daily, monthly, and
frequent inspections. You’re also creating a lot of wear and tear on your crane
that can easily be preventive with routine maintenance. Your overhead crane operators are required to have operator safety training as well. I am willing to bet if your not doing the inspections then your definetly not doing the training either. This is how accidents happen. Having cranes that are not maintained and operators that are not trained. Not only is it against regulations, you are putting your employees at great risk. Take the time to know what inspections are required of your crane. Talk to a reputable overhead crane company that can consult with you and help ensure that your cranes are inspected at the correct frequency.
