Cranes are among the most powerful and potentially hazardous pieces of equipment on construction sites and in industrial facilities. OSHA reports that crane-related incidents cause an average of 42 fatalities and thousands of injuries each year in the United States. Proper inspections at every level — before each shift, monthly, and annually — are critical for preventing structural failures, dropped loads, and tip-overs. This guide covers the OSHA requirements for crane inspections, what to include in each type of inspection, and provides a free downloadable checklist.
Free Crane Inspection Checklist
Download our Word document checklist covering shift, monthly, and annual inspection items for overhead, mobile, and tower cranes.
Download Checklist (.docx)Why Crane Inspections Are Required
OSHA 29 CFR 1926.1412 — Cranes and Derricks in Construction
This is the primary standard governing crane inspections on construction sites. It applies to all power-operated equipment that can hoist, lower, and horizontally move a suspended load, including mobile cranes, tower cranes, and derricks. Key requirements:
- Each Shift (1926.1412(d)): A competent person must perform a visual inspection before each shift covering control mechanisms, safety devices, wire rope, hydraulic and pneumatic lines, hooks, electrical systems, tires, and ground conditions.
- Monthly (1926.1412(e)): Items from the shift inspection must be documented at least monthly. Documentation must be retained for three months. Deficiencies must be evaluated by a competent person.
- Annual/Comprehensive (1926.1412(f)): A comprehensive inspection by a qualified person at least every twelve months. Documentation must include items checked, results, inspector name and signature, and date. Records retained for twelve months minimum.
OSHA 29 CFR 1910.179 — Overhead and Gantry Cranes
This standard covers overhead and gantry cranes in general industry settings such as manufacturing plants and warehouses:
- Frequent Inspections (1910.179(j)(2)): Daily to monthly intervals covering operating mechanisms, air or hydraulic systems, hooks, hoist chains, and rope reeving.
- Periodic Inspections (1910.179(j)(3)): One to twelve month intervals depending on service severity, covering deformed or cracked members, loose bolts, sheaves, worn drums, bearings, brake system parts, electrical apparatus, and load hooks.
OSHA 29 CFR 1910.180 — Crawler, Locomotive, and Truck Cranes
This standard covers crawler, locomotive, and truck cranes in general industry with similar frequent and periodic inspection requirements. It specifies both operator-level daily checks and more detailed engineering inspections at periodic intervals.
Pre-Shift / Daily Inspection Items
A competent person must perform this visual inspection before each shift that the crane is used. Any deficiency constituting a safety hazard requires the crane to be taken out of service until corrected.
| Inspection Item | What to Check |
|---|---|
| Control mechanisms | All controls respond correctly. No sticking, excessive play, or maladjustment. Emergency stop functions properly. |
| Safety devices and operational aids | Anti-two-block device, load moment indicator (LMI), boom angle indicator, level indicator, and limit switches functional and not bypassed. |
| Wire rope | No kinks, bird-caging, broken strands, crushing, or excessive wear. Proper reeving. Meets 29 CFR 1926.1413 criteria. |
| Hooks and latches | No cracks, deformation, or throat opening exceeding 15% of original dimension. Safety latch present and functional. No twist exceeding 10 degrees. |
| Hydraulic and pneumatic lines | No leaks, cracks, bulging, or abrasion on hoses and fittings. Connections secure. Fluid levels adequate. |
| Electrical apparatus | No malfunctioning, visible deterioration, dirt or moisture accumulation on electrical components, connections, and conductors. |
| Tires and outriggers | Tires properly inflated and in good condition. Outriggers/stabilizers functional and properly deployed on adequate cribbing or pads. |
| Ground conditions | Adequate ground support under and around outriggers. No settling, water accumulation, or undermining. Level within manufacturer tolerances. |
| Boom and jib | No visible cracks, bends, or deformation in boom sections or jib. Boom pins and keepers in place. Pendant lines properly attached. |
| Hoist brakes | Hold load at rated capacity. No slipping, grabbing, or unusual noise. Both service and holding brakes tested. |
| Swing mechanism | Smooth rotation without binding or unusual noise. Swing brake holds and releases properly. Swing lock engages. |
| Warning devices | Horn or audible signal operational. Backup alarm functional. Rotating beacon or warning lights working (if equipped). |
| Load chart | Current and legible load chart posted in the cab matching the crane's configuration (boom length, counterweight, outrigger position). |
| Operator cab | Windows clean and unobstructed. Fire extinguisher present and current. Mirrors adjusted. Cab free of loose items. |
Monthly Inspection Items
In addition to all daily inspection items, the monthly inspection must be documented and must include a more thorough examination of the following components:
| Inspection Item | What to Check |
|---|---|
| Structural members | Deformed, cracked, or corroded members. Loose bolts or rivets. Check welds for cracks. Measure boom deflection if applicable. |
| Sheaves and drums | Worn or cracked sheaves, excessive groove wear, damaged flanges. Drum flanges and grooves, proper spooling, rope anchoring. |
| Bearings | Excessive play, noise, or heat indicating wear. Lubrication adequate. Slewing bearing condition (tower and mobile cranes). |
| Brake system components | Brake linings, drums, and pins. Measure lining thickness against minimum. Verify adjustment and operation of all brakes. |
| Electrical systems | Contactors, limit switches, relays, and controllers. Wiring condition, connections, and grounding. Pendant control condition. |
| Wire rope terminations | End connections, wedge sockets, swaged fittings, and clips inspected for proper installation and condition. |
| Travel mechanism | Track, wheels, axles, and drive components. Rail clamps and anchoring devices (gantry cranes). Travel brakes. |
| Counterweight | Properly secured and at correct weight. No shifting or damage. Mounting hardware in good condition. |
Annual / Comprehensive Inspection
The annual comprehensive inspection must be performed by a qualified person and may require disassembly or nondestructive testing of critical components. In addition to all monthly items, this inspection covers:
Annual Inspection Scope
- Complete structural inspection including NDT (magnetic particle, ultrasonic, or dye penetrant) of critical welds and connections
- Load testing per manufacturer specifications or applicable ASME B30 standards
- Full evaluation of all safety devices and operational aids calibration
- Complete wire rope inspection with replacement criteria per 1926.1413
- Hydraulic system pressure testing and cylinder inspection
- Detailed electrical inspection including insulation testing
- Review of all operating manuals, load charts, and safety documentation
- Full brake testing under load conditions
- Review and update of maintenance history and previous inspection findings
Corrective Actions
When a crane fails any inspection item, prompt and documented action is required:
Safety Hazard Identified
- The crane must be immediately taken out of service per 29 CFR 1926.1417
- Tag the crane with "Do Not Operate" or equivalent lockout/tagout
- Notify the site supervisor and safety manager
- Document the deficiency on the inspection form with specific details
- The crane may not be operated until a qualified person verifies the repair
Non-Hazardous Deficiency
- If a competent or qualified person determines the deficiency is not a safety hazard but needs monitoring, it must be checked in subsequent monthly inspections
- Document the deficiency and the rationale for continued operation
- Schedule repair during the next maintenance window
- All repairs must be performed by qualified maintenance personnel
Best Practices
Operator Qualification
OSHA 29 CFR 1926.1427 requires crane operators on construction sites to be certified by an accredited testing organization. Operators should be trained on the specific crane model they operate and should actively participate in shift inspections. Training management software can track operator certifications, expiration dates, and continuing education requirements.
Documentation and Recordkeeping
Maintain separate inspection records for each crane identified by serial number or unique asset ID. Digital inspection records are preferred for searchability, trend analysis, and audit preparation. Inspection software automates scheduling, documents findings with photos, and tracks corrective actions through completion.
Wire Rope Management
Wire rope is the most commonly cited crane component in OSHA inspections. Follow 29 CFR 1926.1413 for detailed wire rope inspection criteria, including broken wire thresholds, diameter reduction limits, and corrosion assessment. Replace wire rope that meets any single rejection criterion.
Download the Free Checklist
Get our crane inspection checklist in Word format. Covers shift, monthly, and annual inspection items for all crane types.
Download Checklist (.docx)Ecesis EHS Software
Inspections
Digital inspection forms with mobile completion, photo capture, and corrective actions.
Safety Inspections
Workplace safety inspections with automated scheduling and deficiency tracking.
Preventive Maintenance
Schedule and track crane maintenance, wire rope replacement, and annual certifications.
Training
Track operator certifications, signal person qualifications, and rigger training.
Compliance Calendar
Track inspection deadlines, annual certification dates, and recurring maintenance.
Task Management
Assign and track corrective actions from failed inspection items to completion.
