An Interview With A Crane Inspector

When I go to a customer’s site I never look at myself as a salesman. I look at it more that I am a consultant to my customer. I try to show them the appropriate steps that they need to take to be compliant, safe, and proactive in with their crane maintenance. I try to see what their needs are and try to find the perfect fit for them. I never try to sell them something that they don’t need, nor do I push anything unless I have established a relationship with that customer, and it is a safety issue.


One issue I have faced as a salesman a few times is the fact that I am not always taken as serious as if I was an inspector or technician. Coming in as a salesman especially with someone that I have not developed a relationship with and try to convince them of what they need is not always the easiest thing to do. You get those looks like you’re just a sales guy trying to sell them something. Sometimes I feel like I could get more across to a customer when I was a technician.

At my work I am fortunate to have a lot of talent out in the field that I can rely on when I have questions regarding cranes, and various regulations on them. We have a very knowledgeable work force that is out their working on our customers cranes every single day. The training program we have in place is unsurpassed by any competitor. We have our own crane institute that is designed for all careers at our company from technician, to inspector, or manager to salesman. Barry Conway is one of those guys that I rely a lot. I know if a customer asks me something that I am not sure of, Barry is the first person that I call. I know he will either know the answer or at least know where to find the answer. He is a valuable asset to our organization and that is why I wanted to do my first interview with him. I know what my answers are to the following questions but I thought the answers were so much more valuable coming from someone who is on the cranes everyday and sees the programs that customers have implemented daily. So lets see what he has to say….

How Long have you been a crane inspector?
I have been an approved and licensed Cal OSHA crane inspector for 21 years and have worked in the crane industry for 26 years.

What do you like about your job?:

I enjoy the places I go, most are very interesting and I have met some very knowledgeable and interesting people along the way.


What is the biggest issue that you find that your customers are unaware of?:

A lot of my customers are unaware of the regulation from Cal OSHA regarding their equipment, the record keeping, the training of the operators, having a maintenance program in place. A lot of the break downs are due to improper operation by the employees. Proper training can reduce or even eliminate them.

What crane discrepancy do you find the most and why do you think that is?:

With new customers I find a lack of record keeping and a lack of proper maintenance of their equipment.. These are both OSHA requirements.

Is there any suggestions that you make to your customers on a regular basis?:

Yes, to start a maintenance program on their small units. There seems to be a misconception that maintenance and record keeping does not need to be performed on units of 6,000 lbs or less. That is not true.

Are there any regulation that you would like to implement or suggest to CAL-OSHA?:

I would like to see more stringent requirements for certifiers implemented. There are a lot of safety devices on cranes. An inspector needs to have a through understanding of how a crane operates and all of the safety devices that are incorporated in them. Some seem to not understand fully about them.

Any additional comments that you would like to make?

A good maintenance program, proper operator training can go a long way in reducing overall expenses and down time. Keeping spare parts on their shelf can reduce down time and reduce other cost by eliminating additional travel time. Brakes, wire ropes, even spare motors and VFD Drives, especially if the unit is a critical crane.



In closing I want to thank Barry for taking the time to answer my questions. It still amazes me that there is such a lack of record keeping with crane equipment. Close to 90% of all crane accidents are fatal. With statistics like that you don’t want to become part of those statistics. The only way to improve your chances is to take care of your equipment, record keeping, and training. It is our job to help companies’ fine tune their record keeping and keep on a strict maintenance schedule. Contact me today and I can help you with your crane needs.

Load Testing Reinstalled Equipment in the State of California.

Recently I had a customer who wanted to have load testing done on his monorails. His monorails were three ton capacity. Now, Load testing in the State of California is required on initial installations and every four years for equipment over three tons. However they often move the hoist to different locations and on different monorails throughout the facility. The question that arose was if we had to load test them every time a hoist gets re-installed on a different monorail.

In a letter from 1994 written by CAL-OSHA they state that if the hoist is not an integral part of the machine, then the monorail does not have to be load tested or certified. Then they go ahead and define a monorail as “a crane whose hoisting mechanism is suspended from, and is an integral part of, one or more trolleys mounted on a single track.” So what the heck does integral mean anyway? OSHA commented to us that this is a confusing part for people trying to interpret what the regulations mean, and I can definitely see why. CAL-OSHA does not explain what they are referring to with the word, “integral”. Even under the definitions it is not listed. What he told us was that if it is not defined in Title 8 then it should be referenced from a dictionary. He went on and referenced Webster’s Dictionary and stated that the term integral as, essential to completeness, 2. Composed of integral parts, 3. Lacking nothing essential. So what I gather from this is that all hoists are integral to any monorail.

The following is an excerpt from the email sent to us from CALOSHA. , A hoisting unit is integral to all monorail cranes. Without a hoisting unit, a monorail crane is not complete and cannot perform its intended function. Section 5022 requires that a proof load test be performed on a monorail crane every four years. It is silent when it comes to reinstalling the hoisting equipment on the monorail crane. ASME B30.11 requires an operational test on reinstalled equipment. It also says that a load test should be performed on reinstalled equipment as determined by a qualified person. The problem is that our code in 4884 requires that such cranes be designed, installed, and constructed to the ASME requirements. Cranes need to be inspected, tested and maintained per Title 8. Since Title 8 is silent on the issue of reinstalled equipment, my opinion is that a load test should be performed based on your recommendation. What does the manufacturer recommend?

So, in the end it is up to the manufacturer’s or crane servicing company’s recommendation. Now he did state that he suggest a load test be performed every four years per Title 8 5022, and a load test on reinstalled equipment be performed as determined by a qualified person as per ASME B30.11. However I don’t really get it. They put all these regs in place and state all these regulations that are required to be followed on all equipment over three tons. Then when asked about it they pretty much say below three tons it should be done as well but it is up to the discretion of a qualified person. I thought that these regulations were in place to keep people from using their own discretion? If my customer comes to me with these questions, I would recommend quarterly inspections on all their equipment but only load testing above 3 ton capacities unless it is a class C or D crane then I would recommend every four years as well. Anything below three ton it really depends on the severity of use of the crane or hoist. If it is used a lot then it really needs to be treated as a piece of equipment that has a capacity over three tons. I’ll leave you with this, do you really think 6,000 lbs is going to hurt any worse than 8,000 lbs?

Crane Inspector Qualifications

So your company wants to cut cost and it has decided to perform their own inspections and preventive maintenance on their overhead cranes and hoist. Why not right? I mean, your company has a maintenance department. They fix everything else in the plant. They fix the cranes when they are broken. That must mean they are fully able to inspect them as well. Well…. Not if you’re going to go by the rule book, the latest and greatest CMAA standard (Spec 78) which is one of the many specs that is followed by OSHA. OSHA does not know all and they need other committees to help them put together these regulations. CMAA is an association developed by the Crane Manufacturers Service Committee. They are highly knowledgeable committee that is led by the leaders in the industry. According to CMAA there are many qualifications that are required for crane inspectors including physical requirements, work experience, required training, and even local licensing. Let’s take a deeper look at the various requirements so you can understand the burden you will be carrying performing your own inspections.

There are several physical requirements that are set by CMAA for crane inspectors. Some of the more understood qualifications is proficiency in reading and writing English, proficient oral and written communication skills, and be able to distinguish between colors, and have adequate hearing for the job, and physical dexterity, endurance, and strength. There are other qualifications that may not be known like the specifics of the vision qualifications. You are required to have 20/30 minimum in one eye and 20/50 in the other. This is with our without corrective lenses. Your depth perception has to be within normal range, including your field of vision, hand-eye coordination, with no existing conditions of dizziness. You also have to be subject to a safety and drug program. Therefore if your company does not have one in place or it is not that assiduous, then they will need to step up their program even if you only have one employee inspecting your crane. Heights are an additional requirement that gets overlooked probably because it seems so obvious. Your inspector must be comfortable working at heights to access the crane. He has to understand the safety requirements for this, and be able to work safely under adverse physical conditions. It can get extremely hot at the height of the cranes in the plant. So it is immensely important that the inspector understands this and can physically handle the conditions that he or she will be working in. The last physical requirement is fairly understood and most companies adhere to this when hiring maintenance personnel. You can have no physical restrictions of any kind. Meaning… you have to have control of all your body functions at all times, and total emotional stability. I would like to think that companies do not hire people for maintenance personnel outside of such a requirement, but I know that all companies work differently. It is very important for the company to follow these qualifications for the safety of their employees.

Work experience of the inspector is not only something that many companies don’t follow for their maintenance crew but many crane servicing companies do not follow this as well. CMAA requires your inspector to have a minimum of “2,000 field hours of experience related to the maintaining, servicing, repairing, modifying, and functional testing of cranes and associated hoisting equipment”. If you do outsource your crane inspections you should ask your vendor how many hours their inspectors have. They should have well over 2,000 hours if they are inspecting your equipment. On top of these qualifications they should have a good understanding of the various codes and regulations on the overhead cranes set by OSHA, CMAA, and ANSI.

Lastly, we get into the required training that CMAA has set as minimum qualifications to be an inspector. This training however means nothing if any of the prior mentioned are not met. Your employee may have extensive training but if the work experience is not there or the physical requirements cannot be met, then the training of the employee means nothing. You need to have all three in order to be qualified to inspect overhead crane equipment. The training of the inspector is no less arduous than the physical or experience qualifications. It is required for the inspector to have formal training in codes and regulation at Federal, State, and local level. The inspector has to be very discerning with the various codes and regulations set forth by OSHA, CMAA, ANSI, and local committees. They are required to take refresher courses every two years to get acquainted with revisions that change annually. They need to know the difference between “Shall” and “Should”, which can complicate issues greatly if they misinterpret the two. It is essential for the inspector to have trade skills as well which comes from their work experience. The inspector has to have a working knowledge of the products and equipment that they are inspecting. This will help them identify wear patterns, and hear things that may be out of the ordinary. Safety is another important training subject that needs to be familiarized by the inspector as well. This is for their own good to make sure that they work safe, and understand if certain operations of the equipment is unsafe. This would include the astuteness of job-site conduct. Testing of all these training topics is required so the inspector can demonstrate his proficiency of these topics. Certain local governments will require the inspector to be licensed as well, so make sure you check with your local government agencies to ensure if they will need a certification or license to inspect your equipment.

I have discussed several points that CMAA requires inspectors to be qualified in. With all these issues mentioned, please re-think your option to inspect your equipment yourself. Yes, you may save money short term by performing your own inspections. However to do it properly the money spent on your inspector is great, and the responsibility that you are giving yourself far exceeds the few dollars that your saving doing so. If you’re going to go and follow the regulations by doing periodic inspections on your overhead cranes, then seriously think about the burden of doing this on your own. Us crane guys are here to help you, and we want you to make the right choices for your company. In the very least contact your crane vendor and discuss with them the option to perform the periodic inspections on your own.

Requirements For Inspecting Cranes Three Ton and Below In California

Since I have been working out of California, I have had a lot of questions regarding the inspections and maintenance on equipment that is below three ton capacity. Because the CALOSHA Title 8 Article 100 specifies hoisting equipment over three tons. This article states that all equipment over three ton shall be quarterly inspected and have a load test performed every four years. Because of this many people do not inspect or have any maintenance plan of any kind on their equipment that is below three tons. I was very surprised by this since in reality it made no sense at all. Typically most manufacturing plants main lifting equipment is below three tons. Also this equipment is generally what is most widely used in the plant. So why not have a maintenance and inspection schedule on them?

Recently I was introduced to a letter from CALOSHA that written back in 1993. This letter was regarding proof load testing on cranes less than three tons capacity. It does state that equipment over three tons only requires quadrennial load testing. However is required that all equipment below three tons still be on a maintenance schedule regardless of the rated capacity. Many contractors in the state of California will tell you that you do not need to worry about inspecting your equipment that fall at three tons or less rated capacity. These inspectors and contractors are ill informed.

When you are putting together your inspection program on your overhead lifting equipment in the state of California, make sure that you include all lifting equipment regardless of the rated capacity. Doing your equipment over three tons is not satisfying CALOSHA requirements. Even worse, it is extremely dangerous to not have a maintenance schedule for your lifting equipment. Please let me know if you need help putting together a maintenance schedule. I will gladly help you put together a program that is economic, efficient, safety conscious, and CALOSHA satisfied, all while keeping your production needs in the forefront!

Huge Crane Fall In Portugal

This is what not to do when rigging a load. Especially a big one like this. You can tell it was extremely top heavy. Never rig from the bottom of the load!!!

Runway Alignment

One of the crane system components that often get overlooked is the runway. Often cranes will have wheel problems and the wheels get changed out not thinking of the actual runway being a potential reason for the original wheel wear. If your crane travels down the runway and is very loud, and you hear lots of cracking, and racking of the crane, you probably have a runway issue. Sometimes the crane runs silently down the runway and you still could have potential crane rail issues.


CMAA specification No. 70-2004 1.4 gives some good guidelines for your runway. It is a must that the runway be “straight, parallel, level and at the same elevation”. If any one of these factors is out of skew it can affect the performance of the crane or cause premature wear. The span of the runway is also a important dimension that if is not within tolerance will cause premature wear as well, and also cause racking of the crane. If your span is less than 50’ as most cranes are, you are only allowed a overall tolerance of 3/16 “. From 50’ to 100’ you are allowed ¼” of tolerance, and if it is over 100’ span than you have up to 3/8”. If you think about that is such a small tolerance over such a distance. You are allowed a ¼” rate of change maximum for every 20’ of runway. When your rail is no straight it is extremely hard on your wheels and brakes when it constantly racks. Your runway elevation should be within 3/8” on each side of runway, and same as crane span when it is compared to each other. Meaning your rail to rail elevation on a crane less than 50’ can only be out by 3/16”, between 50’ and 100’ you’re allowed ¼”, and same with a 100’ you’re allowed 3/8” with a maximum rate of change of ¼” on 20’.

Another important dimension to keep in mind is the space between the rails. The CMAA standards are 1/16”. However the larger the rail and the larger the wheel the greater dimension you will be allowed to get away with. CMAA does not deviate from that dimension. I have seen the dimension larger than this and it has not created any issue with wheel wear or noise during travel because the rail was 160# rail and the wheel had a diameter large enough that it was not affected by the gap.

Konecranes has designed a new and efficient way to perform a runway analysis called Rail Q. From their website page http://www.konecranesamericas.com/news/1/26/ I have learnt several things that would be beneficial for any company with a rail concern to look into Rail Q. Rail Q is much more accurate than previous ways to perform runway analysis. It is also quicker. This would minimize the downtime of your crane during the analysis, and reduced cost of the analysis. Results from such a precise analyisis offer the customer a more cost effective means of repairs to get the runway within tolerance.



Below is an introductory video of the Rail Q survey. Please take a look.



Rail Q Survey

Where do I find regulations for Overhead Cranes?

OSHA 1910.179 is the main source for your overhead crane regulations. All other forms of regulations were either written to clarify or expand on the existing OSHA 1910 regulations. These regulations cover definitions of cranes and it’s components, general requirements, cabs, footwalks and ladders, stops, bumpers, rail sweeps, and guards, brakes, electrical equipment, hoisting equipment, warning devices, inspections, testing, maintenance, rope inspection, handling the load, and other general requirements.

CALOSHA Title 8 was written by the California OSHA as a supplement to the OSHA 1910.179 standards. CALOSHA over-rides all OSHA regulations that contradict one another. The California OSHA made these regulations because certain parts of the OSHA 1910.179 they felt were not stringent enough so they wrote a more stringent set of standards to protect the users of this equipment. Obviously this is lawful only in the state of California. If your state has its own OSHA department then you may have similar supplements to OSHA 1910.179. Here you will find similar regulations that are in OSHA. You should look here first when you’re in the State of California. If you don’t find it here then go to OSHA 1910.179. Operation, Testing, Maintenance, and Inspections of overhead cranes are the three big amendments that CALOSHA made to the OSHA regulations.

ASME B30 was written to expand on monorails and under-running cranes which is not specified in OSHA 1910.179. ASME (American Society of Mechanical Engineers) B30 were written for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings under the accreditation by ANSI (American National Standard). ASME B30 covers general construction, installation, inspections, testing, maintenance, operation, and definitions of monorails, under-running cranes, and its components. ASME B30 over-rides OSHA 1910.179. If you are found in violation of an OSHA regulation that contradicts ASME then you do not get fined.

CMAA 70-2004 (Crane Manufacturers Association of America) are specifications for top running bridge and gantry cranes including multiple girder cranes. These specifications were written by crane manufacturers to promote a standardization of cranes and equipment. This does not only spec manufacturing recommendations but also technical procedures. The CMAA Specification number 70-2004 has six main sections.

1. General Specifications

2. Crane Service Classification

3. Structural Design

4. Mechanical Design

5. Electrical Equipment

6. Inquiry Data Sheet and Speeds

You would look into NEC 610.31, and 430.101 through 430.113 to get the specifications for electrical disconnect regulations. You could also look into NFPA 70E for De-contactors for maintenance purposes which would include hazard analysis, voltage testing and auxiliary disconnects, mechanical interlocks, flash boundaries, and PPE.

If you have any questions or need further assistance please let me know and I will do my best to provide you with the information that you request. I hope this has been helpful.