Pre-Shift Inspection for Cranes and Hoists

Manual Lifting & Material Handling
English (US)

The Problem

Overhead cranes and hoists are essential for lifting heavy loads, but if they are not inspected before use, small unnoticed issues can lead to catastrophic accidents, injuries, or even fatalities. A thorough pre-shift inspection is the key to identifying problems early and ensuring safe operations. Today, we will go step-by-step through the inspection process to ensure we can spot hazards and take appropriate action.

Identify the Hazards

  • Structural Failures: Cracks, bends, or broken parts can cause crane collapse.

  • Load Drops: Damaged hooks, faulty latches, or worn ropes can lead to dropped
    Loads.

  • Mechanical Failures: Leaks, brake malfunctions, and control failures jeopardize load control.
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  • Electrical Hazards: Damaged power cables expose workers to shock risks.

Safety Practices and Preventative Measures

To prevent accidents, follow these critical pre-shift inspection steps:

  1. Visual Inspection for Structural Damage:

    • Check the crane and hoist for cracks, loose bolts, or broken parts.
    • Action: Report structural damage immediately. Do not operate unsafe equipment.
  2. Inspect Wire Ropes or Chains:

    • Look for fraying, kinks, or wear that could compromise lifting strength.
    • Action: If wear is excessive, tag out the equipment for repair.
  3. Check for Leaks:

    • Look for oil or fluid leaks that may indicate mechanical failure.
    • Action: Report leaks for maintenance before use.
  4. Inspect Power Cables and Connectors:

    • Check for damaged insulation, exposed wires, or faulty connectors.
    • Action: Remove equipment with damaged cables from service immediately.
  5. Verify the Load Rating Plate:

    • Ensure the load rating plate is present, legible, and not exceeded.
  6. Check the Hook:

    • Look for cracks, deformation, or twisting in the hook.
    • Action: Damaged hooks must be replaced immediately.
  7. Test the Hook Latch:

    • Ensure the latch or safety catch engages and releases properly.
    • Action: Do not use equipment with faulty latches.
  8. Test Control Buttons and Switches:

    • Verify that all controls are responsive and functioning.
    • Action: Report unresponsive controls for repair.
  9. Test Hoist Operation:

    • Move the hoist slowly to check for unusual noises or jerky movements.
    • Action: Investigate any irregularities before use.
  10. Verify Travel and Load Brakes:
  • Test that the brakes engage and hold the load properly.
  • Action: Tag out equipment with faulty brakes.
  1. Test the Upper Limit Switch:
  • Inch the hoist to verify that the limit switch stops movement as required.
  • Action: Malfunctioning limit switches must be repaired.
  1. Verify Safety Devices:
  • Ensure warning horns, alarms, and other safety devices are working.‍
  • Action: Report malfunctioning safety devices immediately.

Real-Life Case or Scenario

Where possible, use an actual incident that you have experienced or been involved in.

A team once skipped a pre-shift inspection of a crane. During a lift, a damaged wire rope snapped, causing the load to drop and injure a worker. This incident could have been avoided with a thorough inspection that identified the worn rope before use. Pre-shift inspections save lives.

Employee Responsibilities

  • Conduct a thorough pre-shift inspection before operating cranes or hoists.
  • Immediately report any defects, leaks, or malfunctions to your supervisor.
  • Tag out defective equipment to prevent use.

Employer Responsibilities

  • Provide properly maintained cranes and hoists.
  • Ensure inspections are completed daily and train employees on inspection procedures.
  • Repair or replace defective equipment promptly.

Discussion & Questions

  • "What’s the most common defect you’ve encountered during a crane inspection?"
  • "Have you ever tagged out a crane or hoist due to safety concerns? What steps were taken next?"

Commitment/Action Plan

Let’s commit to performing thorough pre-shift inspections every day. Starting today, double-check each crane and hoist for hazards before use and report anything out of order immediately. By working together, we can prevent accidents and ensure a safer job site.

Wrap-Up

Pre-shift inspections are not just a formality—they are a critical part of safety. By taking a few extra minutes to inspect your equipment, you can prevent accidents, protect your coworkers, and keep the job site safe. Thank you for your attention and commitment to safety.

Standards Overview

  • OSHA standards (OSHA 1910.179 and ASME B30.2) require that overhead cranes and hoists be inspected regularly to ensure they are safe for use.
  • Employers and employees are responsible for inspecting the equipment before each shift and removing any unsafe equipment from service.
  • Failure to perform inspections can lead to severe accidents and OSHA violations.

Disclaimer

“The information provided in this toolbox talk is provided for informational and educational purposes only. It is not intended to be a substitute for professional legal, safety, or regulatory advice. The information presented is based on best practices and general industry standards but may not apply to all workplace situations.
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It is the responsibility of the employer, supervisors, and workers to ensure compliance with applicable federal, state, and local laws, regulations, and standards, including but not limited those of the Occupational Safety and Health Administration (OSHA). Site App Pro, its affiliates, agents or representatives, as well as the authors, presenters, and distributors of this toolbox talk assume no liability for the use or application of the information provided.
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Participants are encouraged to consult appropriate legal, safety, or regulatory professionals to address specific concerns or questions. Always follow your organization's policies and procedures for workplace safety and hazard mitigation.”

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Last Updated:
January 13, 2025