Pre-Shift Inspection for Cranes and Hoists
The Problem
Overhead cranes and hoists are essential for lifting heavy loads, but if they aren’t inspected before use, minor issues can quickly lead to serious accidents, injuries, or fatalities. A thorough pre-use inspection is the key to identifying faults early and ensuring safe operations. Today, we’ll go step-by-step through the inspection process to help spot hazards and take appropriate action.
Identify the Hazards
- Structural Failures: Cracks, bending, or broken components can cause crane collapse.
- Dropped Loads: Damaged hooks, faulty latches, or worn ropes can cause the load to fall.
- Mechanical Failures: Leaks, brake failures, or faulty controls can result in loss of control.
- Electrical Hazards: Damaged power cables can cause electric shock.
Safety Practices and Preventative Measures
1. Visual Inspection for Structural Damage
- Check for cracks, loose bolts, and broken components.
Action: Report any structural damage immediately. Do not use the equipment.
2. Inspect Wire Ropes or Chains
- Look for fraying, kinks, rust, or wear.
Action: Tag out and report excessive wear.
3. Check for Leaks
- Look around the crane and hoist for any signs of hydraulic or oil leaks.
Action: Report and repair before operating.
4. Inspect Power Leads and Plugs
- Look for exposed wires or damaged insulation.
Action: Remove faulty equipment from service.
5. Verify Load Rating Plate
- Ensure it is present, clear, and legible. Never exceed the rated capacity.
6. Inspect the Hook
- Look for cracks, distortion, or wear.
Action: Replace damaged hooks immediately.
7. Test the Safety Latch
- Make sure it opens and closes securely.
Action: Faulty latches must be reported and repaired.
8. Test Control Buttons and Switches
- All control functions should be tested before starting a lift.
Action: Report unresponsive controls straight away.
9. Test Hoist Operation
- Lift slowly to check for abnormal sounds or movement.
Action: Stop and report any irregularities.
10. Test Brakes
- Ensure the brakes engage and hold the load.
Action: Faulty brakes = no-go.
11. Test Upper Limit Switch
- Inch the hoist to check that the upper limit switch engages.
Action: Do not operate if it fails.
12. Confirm Safety Devices Are Working
- Horns, alarms, or any emergency shutoffs must be tested.Action: Report any faults.
Real-Life Case or Scenario
On a recent job, a team skipped the crane inspection. A worn wire rope snapped mid-lift, dropping the load and injuring a worker. This incident would’ve been prevented with a simple inspection that morning. Pre-use checks save lives—don’t skip them.
Employee Responsibilities
- Inspect cranes and hoists thoroughly before every use.
- Tag and report any faults or hazards immediately.
- Never operate defective or unsafe equipment.
Employer Responsibilities
- Ensure cranes and hoists are properly maintained and inspected.
- Provide training on pre-use inspections and lifting safety.
- Promptly repair or replace damaged equipment.
Discussion & Questions
- "What’s the most common fault you’ve come across during crane inspections?"
- "Have you ever had to tag out a crane? What happened next?"
- "What’s one thing we can improve about our current inspection process?"
Encourage the team to share examples and concerns.
Commitment/Action Plan
From today, commit to doing a proper pre-use inspection on every crane or hoist before operation. If you spot anything wrong—no matter how minor—tag it out and report it. Take those extra few minutes to ensure everyone goes home safe.
Wrap-Up
Pre-use inspections are not a tick-box exercise—they are a vital safety step. Every hazard you catch during inspection is one less risk on site. Thanks for staying sharp and keeping safety front of mind.
Standards Overview
WorkSafe NZ requires that lifting equipment be inspected before use and regularly maintained.
Relevant regulations include:
- Health and Safety at Work (General Risk and Workplace Management) Regulations 2016
- AS/NZS 1418.1: Cranes, hoists and winches – General requirements
Employers and PCBUs must ensure lifting equipment is safe to operate and workers are trained in its safe use.
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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