Frequency and Type of Crane Inspection

A major factor in determining the cost of an overhead crane inspection is the frequency, or type of crane inspection, that is being performed. Knowing how often your overhead cranes need to be inspected is one of the first steps in determining the criteria for inspection and how often it will be performed. Developing an inspection program that will meet compliance requirements for OSHA, ASME, and CMAA standards will help to keep you compliant for overhead crane inspection—scheduling only one annual inspection will not.

Inspection frequency is based on crane service, environmental factors, and application factors according to OSHA 1910.179:

“Inspection procedure for cranes in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals, in turn, are dependent upon the nature of the critical components of the crane and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as ‘frequent’ and ‘periodic’ with respective intervals between inspections…”

The section highlighted in bold above is the most critical piece of this statement. Specifically, “the degree of their exposure to wear, deterioration, or malfunction.” The degree of exposure of the crane’s critical components is determined by the duty cycle of the crane, or crane service classification, as determined by CMAA:

• Class A (Standby or Infrequent Service) – This equipment, including installation and maintenance cranes, usually operates at slow speeds for precise handling with long idle periods between lifts. Maximum capacity lifts are sometimes required.
• Class B (Light Service) – This class of equipment includes cranes in repair shops, light assembly operations, service buildings, light warehousing, etc. and service requirements are light and the speed is slow. Loads vary from no load to occasional full-rated loads with 2-5 lifts per hour, averaging 10 feet per lift.
• Class C (Moderate Service) – In terms of numbers, most cranes are built to meet Class C service requirements, including cranes used in machine shops or paper mill machine rooms. These types of cranes will handle loads that average 50% of the rated capacity with 5-10 lifts per hour, averaging 15 feet per lift.
• Class D (Heavy Service) – Typical examples of these types of crane include ones used in heavy machine shops, foundries, fabricating plants, steel warehouses, container yards, lumber mills, etc. These types of cranes constantly handle loads approaching 50% of the rated capacity. High speeds are desirable for this type of service with 10-20 lifts per hour, averaging 15 feet, with not 65% of the lifts at rated capacity.
• Class E (Severe Service) – This equipment is a top riding bridge or gantry type multiple girder electric overhead crane. Applications include magnet, bucket, or magnet/bucket combination and are most commonly found at scrap yards, cement mills, lumber mills, fertilizer plants, container yards, etc. This service class requires a crane capable of handling loads approaching the rated capacity throughout its life with 20 or more lifts per hour at or near rated capacity.
• Class F (Continuous Severe Service) – This equipment is a top riding bridge or gantry type multiple girder electric overhead crane. Applications include custom-designed specialty cranes essential to performing critical work task affecting the total production facility. These cranes must be capable of handling loads approaching rated capacity continuously under severe service conditions throughout its life.

So, now that we’ve identified the different types of overhead crane service classifications, we can lay out guidelines for inspection frequency. A crane will go through two types of inspections during the course of a year: Frequent and Periodic. Let’s identify what these types of inspections are, and how often they need to occur:

Frequent inspection – A frequent inspection is a visual and operational inspection performed monthly or as often as daily. Inspection frequency is based on service, environmental, and application factors, as designated by a qualified person.

Periodic inspection – A periodic inspection is a detailed visual and operational inspection where individual components are examined to determine their condition. Inspection frequency can be quarterly to annually and is based on service, environmental, and application factors, as designated by a qualified person.

As you can see, a crane that is in a normal service class may only need a Periodic Inspection once a year and Frequent Inspections semi-annually. Cranes in heavy or severe service classes should have a Frequent Inspection performed weekly and need a Periodic Inspection 2-4 times a year. Determining how often you need to have your cranes inspected will affect the cost of developing an overhead crane inspection program.

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