Ensuring the reliability, safety, and longevity of overhead cranes is crucial for maintaining productivity, worker well-being, and overall profitability in a business. Regular inspections and maintenance are not just regulatory requirements but essential practices for preventing downtime and costly repairs. Here’s a detailed guide on establishing an effective crane inspection and maintenance routine, along with a checklist and record-keeping tips.

Factors Affecting Inspection Frequency

1. Age:
   • Older Cranes: Require more frequent inspections due to wear and potential degradation over time.
   • Newer Cranes: Generally need less frequent inspections initially but should still adhere to a regular schedule.
2. Function:
   • Complex Activities: Cranes performing complex tasks or operating with more components require more frequent inspections to ensure all parts are functioning correctly.
   • Simple Tasks: Cranes with fewer components or performing less complex tasks may have a less frequent inspection schedule.
3. Frequency of Usage:
   • Regular Use: Cranes used frequently should undergo more frequent inspections to manage the wear and tear from constant operation.
   • Rarely Used: Cranes that are infrequently used may have less frequent inspection needs but should still be checked regularly to prevent issues from inactivity.
4. Capacity:
   • High Capacity: Cranes with higher load capacities need more frequent inspections due to the increased risk associated with handling heavier loads.
   • Lower Capacity: Cranes with lower capacities can generally have a less frequent inspection schedule.
5. Downtime:
   • Extended Downtime: Cranes that are out of service for extended periods may need more thorough inspections before being put back into operation to ensure all components are still in good working order.

It is also important to remember that at a minimum a crane should be checked once per year, or more often due the the factors listed above. This is a OHS requirement.

Crane Inspection Checklist

General Inspection Items:

• Horns: Ensure that audible alerts are functional for warning nearby workers of moving loads.
• Warning Lights: Verify that flashing, colored, or strobe lights are operational to visually indicate crane activity.
• Crane Lights: Check that lights mounted on the crane effectively illuminate the work area to enhance visibility and safety.
• Limit Switches: Test to ensure they are properly set to prevent damage to the crane by slowing trolley travel before reaching end-stops.
• Walkways: Inspect for trip hazards and wear. Ensure they are maintained in good condition and verify the need for fall protection.
• Overload Sensors: Confirm that sensors accurately report load weights and are functioning correctly for data collection and future troubleshooting.
• Radio Control: Test for proper operation of remote controls and two-way communication capabilities.
• Collision Avoidance Systems: Ensure these systems are actively monitoring and preventing collisions with end-stops and obstructions.
• Brake Slip Monitoring: Check for accurate documentation of brake slippage and system alerts for necessary adjustments.
• Variable Speed Drives: Verify that drives are providing smooth starts and stops to minimize load swings and mechanical wear.
• Runtime Monitoring: Review data on load magnitude, contactor switch functions, travel distance, total operating hours, and load histograms to determine maintenance needs.

Record Keeping for Inspections

Maintaining accurate records is critical for efficient maintenance and regulatory compliance. Inspection records should include:

• Dates: Document all maintenance work and crane inspections.
• Personnel Information: Include names and certifications of the inspectors or service personnel.
• Type of Work: Record the type of work performed (e.g., electrical, mechanical, or computer system maintenance) and details of parts serviced, refurbished, or replaced.
• Work Orders: Attach official work orders upon completion of inspections to provide evidence of the work done.
• Irregularities: List any issues or irregularities found during the inspection process, along with recommendations for corrective actions.

Conclusion

Adhering to a structured crane inspection and maintenance routine is vital for ensuring safety, reducing downtime, and enhancing equipment longevity. By considering factors such as crane age, function, usage frequency, capacity, and downtime, and by following a comprehensive checklist and maintaining thorough records, businesses can better manage their overhead crane systems and protect their investments.

For any questions or if your are interested in more information regarding inspections please call 780-482-4263 or email info@overheadcranesolutions.com and a member of the OCS team would be happy to assist you.