Crane Safety Checklist

Purpose

This checklist is designed to ensure the safe operation and maintenance of cranes. It covers pre-operation, during operation, and post-operation checks to identify potential hazards and ensure compliance with safety standards [1].

Instructions

Complete this checklist before each shift and as required during crane operation. Mark each item as either satisfactory or unsatisfactory. If an item is unsatisfactory, take corrective action immediately and document it in the 'Corrective Actions' section. Ensure adjustments and repairs are done only by designated personnel 1, 2.

I. Pre-Operation Inspection

A. Documentation & Personnel

• Crane operator is certified and authorized 15, 19.
• Valid inspection and certification are available [2].
• The operator is fully familiar with all crane rules and with the crane mechanism and its proper care [3].
• The operator is able to communicate with others at the worksite sufficiently to understand the signs, notices, operation instructions, and the signal code in use to ensure safe operation of the crane [4].

B. Crane Structure & Components

• Deformed, cracked, or corroded members in the crane structure and boom are absent 13, 14.
• Loose bolts or rivets are absent 13, 14.

C. Functional Operating Mechanisms

• All functional operating mechanisms are checked for maladjustment interfering with proper operation 3, 13.
• All functional operating mechanisms are checked for excessive wear of components [5].
• All safety devices are checked for proper function 11, 13.
• Deterioration or leakage in air or hydraulic systems is checked 3, 13.
• The hydraulic system is checked for proper oil level [6].
• Electrical apparatus is checked for malfunctioning, signs of excessive deterioration, dirt, and moisture accumulation [7].

D. Hooks and Load Attachment

• Hooks are checked for deformation or cracks 3, 13. Hooks with cracks or having more than 15  in excess of normal throat opening or more than 10 twist from the plane of the unbent hook must be discarded [8].
• Safety latch-type hooks are used or the hook is moused 3, 9.
• Hoist or load attachment chains, including end connections, are checked for excessive wear, twist, distorted links interfering with proper function, or stretch beyond manufacturer's recommendations [5].
• Rope slings, including end connections, are checked for excessive wear, broken wires, stretch, kinking, or twisting [5].

E. Wire Rope

• Wire ropes are inspected according to regulations 1, 2.
• Running ropes are thoroughly inspected at least once a month and a written, dated, and signed report of rope condition is kept on file 1, 2.
• Ropes are checked for reduction of rope diameter below nominal diameter due to loss of core support, internal or external corrosion, or wear of outside wires 1, 2.
• Ropes are checked for a number of broken outside wires and the degree of distribution or concentration of such broken wires 1, 2.
• Ropes are checked for worn outside wires 1, 2.
• Ropes are checked for corroded or broken wires at end connections 1, 2.
• Ropes are checked for corroded, cracked, bent, worn, or improperly applied end connections 1, 2.
• Ropes are checked for severe kinking, crushing, cutting, or unstranding 1, 2.
• Replacement rope is the same size, grade, and construction as the original rope furnished by the crane manufacturer, unless otherwise recommended by a wire rope manufacturer due to actual working condition requirements [8].

F. Crane Environment

• Check route of travel, clearances and ground conditions, including the presence of structures, power lines or other equipment that may constitute a hazard [9].
• Check site of operation, including the nature of ground, gradients, stabilizers, tire pressure and blocking under outriggers [9].

II. During Operation

• The crane is not loaded beyond its rated load, except for test purposes 4, 18.
• The hoist rope is not wrapped around the load 4, 18.
• The load is attached to the hook by means of slings or other approved devices 4, 18.
• The load is well secured and properly balanced in the sling or lifting device before it is lifted more than a few inches 4, 18.
• Hoist rope is not kinked 4, 18.
• Multiple part lines are not twisted around each other 4, 18.
• The hook is brought over the load in such a manner as to prevent swinging 4, 18.
• There is no sudden acceleration or deceleration of the moving load 4, 18.
• The load does not contact any obstructions 4, 18.
• Cranes are not used for side pulls except when specifically authorized by a responsible person who has determined that the stability of the crane is not thereby endangered and that various parts of the crane will not be overstressed [10].
• While any employee is on the load or hook, there is no hoisting, lowering, or traveling 4, 18.
• The operator avoids carrying loads over people 4, 18.
• The brakes are tested each time a load approaching the rated load is handled by raising the load a few inches and applying the brakes 4, 18.
• The load is not lowered below the point where less than two full wraps of rope remain on the hoisting drum 4, 10.
• When starting the bridge and when the load or hook approaches near or over personnel, the warning signal is sounded [4].
• The upper limit switch of each hoist is tested under no load at the beginning of each operator's shift [4].

III. Post-Operation

• All controllers are in the 'off' position and the main switch is open [3].
• If the crane is located out-of-doors, it is locked in a secure position to prevent it from being blown along or off the track by a severe wind [3].

IV. Periodic Inspection (To be completed at intervals as defined in subsection WAC 296-24-24007(1))

• Deformed, cracked, or corroded members in the crane structure and boom are checked [7].
• Loose bolts or rivets are checked [7].
• Cracked or worn sheaves and drums are checked [7].
• Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and locking devices are checked [7].
• Excessive wear on brake and clutch system parts, linings, pawls, and ratchets are checked [7].
• Load, boom angle, and other indicators over their full range, for any significant inaccuracies are checked [7].
• Gasoline, diesel, electric, or other power plants for improper performance or noncompliance with safety requirements are checked [7].
• Excessive wear of chain-drive sprockets and excessive chain stretch are checked [7].
• Travel steering, braking, and locking devices, for malfunction are checked [7].
• Excessively worn or damaged tires are checked [7].

V. Cranes Not in Regular Use

• A crane which has been idle for a period of one month or more, but less than 6 months, has been given an inspection conforming with requirements of subsection WAC 296-24-24007(2) and WAC 296-24-24013 (2)(b) before placing in service [7].
• A crane which has been idle for a period of 6 months has been given a complete inspection conforming with requirements of subsection WAC 296-24-24007(2) and (3) of this section and WAC 296-24-24013 (2)(b) before placing in service [7].

VI. Adjustments and Repairs

• Any unsafe conditions disclosed by the inspection requirements are corrected before operation of the crane is resumed 1, 2.
• Adjustments are maintained to ensure correct functioning of components [11].
• Repairs or replacements are provided promptly as needed for safe operation [11].
• After adjustments and repairs have been made the crane is not operated until all guards have been reinstalled, safety devices reactivated and maintenance equipment removed 1, 2.

VII. Other Safety Measures

• A gong or other effective warning signal is provided for each crane equipped with a powered traveling mechanism except for floor operated cranes [8].
• The crane is standing on track which is level within 1% grade [12].
• A chart indicating the manufacturer's rated capacity at all operating radii for all permissible boom lengths and jib lengths with alternate ratings for optional equipment affecting such ratings is posted and readily visible to the operator in the normal operating position [12].

VIII. Corrective Actions

• Document all corrective actions taken for unsatisfactory items:

  ---

  ---

  ---

IX. Signatures

• Inspector: ____________________________ Date: ____________
• Supervisor: ____________________________ Date: ____________