Crane inspection requirements: shift, monthly and annual

Which crane rule applies

Three OSHA standards cover most cranes, and which one applies depends on the work, not just the machine.

• Construction: 29 CFR 1926 Subpart CC applies to power-operated equipment used in construction that can hoist, lower and horizontally move a suspended load (1926.1400). That includes crawler, mobile, truck-mounted, rough-terrain, boom truck, tower, articulating and overhead cranes and derricks. It excludes excavators, wheel loaders, backhoes and track loaders, even when they lift with slings; aerial devices designed to lift people; and forklifts, except when they're configured to hoist and lower by a winch or hook and move a suspended load horizontally.
• General industry, overhead and gantry cranes: 1910.179.
• General industry, crawler, locomotive and truck cranes: 1910.180.

Slings and rigging have their own daily inspection in both, covered below.

Construction cranes at a glance

Construction cranes get a shift inspection, a monthly inspection and an annual inspection, plus event-driven inspections after modifications, repairs, assembly, severe service or a long idle period (1926.1412).

The shift inspection

A competent person looks the crane over for apparent problems before each shift. Paragraph (d)(1): "A competent person must begin a visual inspection prior to each shift the equipment will be used, which must be completed before or during that shift. The inspection must consist of observation for apparent deficiencies." Taking components apart or booming down isn't required unless what they see or a trial operation calls for it. At a minimum it covers:

• control mechanisms, for maladjustment, wear and contamination;
• air, hydraulic and other pressurized lines, and the hydraulic fluid level;
• hooks and latches, for deformation, cracks, wear or damage;
• wire rope reeving and the wire rope itself (per 1926.1413);
• electrical apparatus;
• tires, when in use;
• ground conditions around the crane, including settling under outriggers and standing water;
• the crane's level position, before each shift and after each move and setup;
• operator cab windows, for cracks that would hamper the view;
• rails, rail stops and clamps on rail-traveling equipment;
• safety devices and operational aids.

If the competent person finds a deficiency that's a safety hazard, "the equipment must be taken out of service until it has been corrected" ((d)(2)). Faults in safety devices and operational aids follow the specific rules in 1926.1415 and 1926.1416. The shift inspection doesn't have to be written down.

Monthly and annual documentation

The monthly inspection is the shift inspection, done and documented once a month: "Each month the equipment is in service it must be inspected in accordance with paragraph (d) of this section (each shift)" ((e)(1)). The record must show "the items checked and the results of the inspection" and "the name and signature of the person who conducted the inspection and the date", and "must be retained for a minimum of three months" ((e)(3)).

The annual inspection goes much deeper. At least every 12 months a qualified person inspects the crane, taking it apart where needed: the structure and welds, sheaves and drums, pins and bearings, brakes and clutches, safety devices, the power plant, chains, travel and steering, tires, hydraulic hoses, pumps, valves and cylinders, outrigger pads, electrical wiring, labels, the operator's seat, and steps, ladders, handrails and guards ((f)(2)), with functional testing ((f)(3)). Deficiencies that aren't yet hazards are flagged for checking in the monthly inspections ((f)(6)). The annual record must be "documented, maintained, and retained for a minimum of 12 months" ((f)(7)).

Two more paragraphs matter. Any part of the manufacturer's inspection procedure that's "more comprehensive or has a more frequent schedule of inspection" than the standard "must be followed" ((j)). And all inspection documents must be available, during their retention period, "to all persons who conduct inspections under this section" ((k)).

Overhead and gantry cranes

Overhead and gantry cranes in general industry get "frequent" inspections at "daily to monthly intervals" and "periodic" inspections at "1 to 12-month intervals" (1910.179(j)(1)), depending on activity, severity of service and environment. Some items have their own schedule:

A crane idle for 1 to 6 months gets a frequent-level inspection before use; one idle over 6 months gets a complete inspection; standby cranes are inspected at least every six months ((j)(4)). Any unsafe condition the inspections turn up "shall be corrected before operation of the crane is resumed", with adjustments and repairs "done only by designated personnel" ((l)(3)(i)), and the employer must run a preventive maintenance program "based on the crane manufacturer's recommendations" ((l)(1)). Our overhead crane inspection checklist covers the daily items.

Crawler, truck and locomotive cranes

The general industry rule for mobile cranes, 1910.180(d), uses the same split: frequent inspections at daily to monthly intervals, and periodic inspections at 1 to 12 months "or as specifically recommended by the manufacturer." Control mechanisms and air or hydraulic systems are checked daily. Certification records "shall be made monthly on critical items in use such as brakes, crane hooks, and ropes", with the date, the inspector's signature and the crane's identifier, and "kept readily available" ((d)(6)). Running ropes get a thorough monthly inspection by "an appointed or authorized person" ((g)(1)). See the mobile crane inspection checklist.

Slings and rigging

Slings are inspected every day before use. 1910.184(d): "Each day before being used, the sling and all fastenings and attachments shall be inspected for damage or defects by a competent person designated by the employer," and "damaged or defective slings shall be immediately removed from service." Alloy steel chain slings also get a thorough periodic inspection at least every 12 months, and the employer must keep a record of "the most recent month in which each alloy steel chain sling was thoroughly inspected" ((e)(3)). On construction sites, rigging "shall be inspected prior to use on each shift" (1926.251(a)(1)). Use the rigging inspection checklist.

Crane and rigging checks on a phone

Shift checks get skipped when the clipboard is in the trailer. With CheckBadges, a QR sticker in the cab or on the pendant opens that crane's checklist on the inspector's own phone, with no app or login, and a rigging rack can have its own sticker too. Every check is filed by machine with the person's name and the time, failed items carry notes and photos, and a problem stays flagged for the next person who scans until it's marked fixed. Where a rule asks for a signature, such as the construction monthly record, print the check and sign it, or confirm with your safety advisor that a typed name or PIN is enough. CheckBadges records inspections; it doesn't schedule the monthly or annual ones.