In the fast-paced and safety-critical world of industrial operations, crane inspections are paramount to ensuring the reliability, efficiency, and above all, the safety of crane equipment. Whether you are a manufacturer, importer, or operator of cranes in China, understanding and implementing a comprehensive crane inspection checklist is essential for preventing accidents, minimizing downtime, and complying with stringent regulatory standards.

This in-depth guide delves into the intricacies of crane inspections in China, covering the various types of inspections, including pre-operational, periodic, and OSHA-compliant checks. You will learn about the critical components to inspect, such as structural integrity, electrical and hydraulic systems, and safety devices. The guide will also outline the importance of load testing, non-destructive testing, and the role of certified inspectors in ensuring compliance with international standards like ISO and OSHA.

Readers can expect to gain valuable insights into pre-purchase considerations, post-purchase inspections, and ongoing maintenance requirements to keep cranes in optimal working condition

Crane Inspection Protocols – China

Crane Inspection Protocols: A Comprehensive Guide

Introduction

Crane inspections are crucial for ensuring the safety, efficiency, and compliance of crane operations. This guide outlines the key protocols and steps involved in conducting thorough crane inspections, particularly for cranes imported from or manufactured in China.

Pre-Inspection Planning

Determining Inspection Frequency and Scope

• The frequency and scope of crane inspections depend on factors such as the type of crane, its usage, and the working environment. Manufacturer recommendations and local regulatory requirements should also be considered[1][2][4].

Gathering Necessary Resources

• Ensure all necessary equipment and documentation are available, including inspection checklists, maintenance records, and relevant regulations or standards. The crane should be out of operation during the inspection[1][2][5].

Visual Inspection

Initial Examination

• Begin with a visual inspection to identify any signs of damage, wear, or defects. This includes examining the structure, wires and ropes, hooks, chains, and other critical components. Look for signs of cracking, corrosion, misalignment, or loose connections[1][2][5].

Critical Components

• Pay special attention to critical components such as:
• Wire ropes and sheaves
• Hooks and load-carrying members
• Control systems and safety devices
• Boom, mast, jib, and outriggers
• Electrical systems, hydraulics, and brakes[1][2].

Functional Testing

Load Testing

• Load testing involves applying a load to the crane to evaluate its capacity and performance under maximum load conditions. This can include:
• Applying a load weighing 1.25 times the rated load of the crane (or 50 tons plus the rated load if it exceeds 200 tons)[3][4].
• Testing the hoisting, traveling, and rotating actions of the crane and the horizontal traveling action of the trolley[3][4].

Stability Testing

• Conduct stability tests by placing a test load weighing 1.27 times the rated load under the most adverse conditions without using runaway prevention devices and rail clip devices[3][4].

Non-Destructive Testing (NDT)

Techniques

• Use NDT techniques such as:
• Magnetic particle testing
• Ultrasonic testing
• Radiographic testing
• Dye penetrant inspection
• These techniques help inspect for defects or weaknesses that may not be visible to the naked eye, especially in critical components like welds, bolts, and structural elements[2].

Post-Inspection Documentation

Inspection Reports

• Generate detailed inspection reports that include:
• A checklist of all inspected components
• Photographs of any defects or issues
• Recommendations for necessary adjustments, repairs, or replacements[1][2].

Maintenance Records

• Keep comprehensive maintenance records, including inspection reports, repairs, maintenance activities, and certifications. This ensures compliance and facilitates future audits[1][2].

OSHA Compliance and Regulatory Inspections

OSHA Requirements

• In the United States, OSHA mandates regular inspections to ensure compliance with safety regulations. These inspections assess the crane’s maintenance, load capacity, and operational safety requirements. Inspections may be triggered by accidents, complaints, or random site selections[1].

Local Regulations

• Adhere to local and international standards (e.g., ISO) and regulations. For example, in Taiwan, cranes must undergo type inspections, completion inspections, and periodic inspections as specified by the labor inspection agency[3][4].

Pre-Delivery and Post-Purchase Considerations

Pre-Delivery Inspection

• Engage a certified and independent third-party inspection agency to conduct a pre-delivery inspection (PDI) of the crane before shipment from China. This inspection should cover all key components and ensure compliance with international standards[1][2].

Post-Purchase Examination

• Upon delivery, conduct a thorough examination to verify the crane’s conformity to agreed specifications, design, and performance requirements. Review the manufacturer’s warranty and service agreement and ensure adequate coverage for potential defects or malfunctions[1][2].

Assembly, Installation, and Commissioning

• Assign a competent person to oversee the crane assembly, installation, and commissioning process. This person must have a detailed understanding of the crane’s specifications, operation, and safety requirements[1][2].

Periodic Inspections

Annual and Periodic Inspections

• Conduct annual or periodic inspections as recommended by the manufacturer or local regulatory authorities. These inspections are more comprehensive and cover all aspects of the crane’s structure, components, and systems[2][4].

Application and Compliance

• Apply for periodic inspections at the inspecting organization before the expiry of the qualification certificate. Cranes should not be operated if the inspection is not applied for within the time limit or if it does not pass the test[3][4].

By following these protocols, you can ensure that your cranes are safe, efficient, and compliant with all relevant regulations, protecting both your workforce and your operations.

Crawler Crane Daily Inspection Checklist – Factory, Suppliers …

Crawler Crane Daily Inspection Checklist: A Comprehensive Guide

Introduction

Conducting daily inspections on crawler cranes is crucial for ensuring the safety and efficiency of crane operations. This guide outlines the key areas and steps involved in a thorough daily inspection.

Pre-Inspection Preparation

Before starting the inspection, ensure you have the necessary documentation and tools:
– Review the crane’s maintenance records and previous inspection reports.
– Gather the operator’s manual, capacity charts, and any other relevant documents.
– Ensure you have a camera for taking photos and a means to record your findings.

Crane Information and Historical Data

Unit Details

• Record the machine unit number, work order number, and the date and time of the inspection.
• Note the location where the inspection is being conducted.

Historical Data

• Check the annual inspection date and review any pictures or documents from previous inspections.
• Record the hours logged on the hour meter and note when the crane was last serviced.

Cab Inspection

General Condition

• Inspect the overall condition of the cab, including any signs of damage or wear.
• Check the fuel level and note any fuel added.

Safety and Operational Items

• Verify the presence and condition of:
• Fire extinguisher
• Operator’s manual
• Capacity chart
• Windshield wiper
• Heater
• Horn
• Air conditioner
• Control levers
• Instrument panel
• Pedals
• Door and latches

Additional Checks

• Ensure the seat and seatbelt are in good condition.
• Check the condition of the glass and any armrest switches.

General Inspection

Exterior Condition

• Inspect the sheet metal for any damage or corrosion.
• Check guards and covers for proper installation and condition.
• Verify that safety and warning decals and labels are clean and legible.
• Inspect external lights to ensure they are functioning correctly.
• Assess the general housekeeping around the crane.

Paint and Corrosion

• Check the paint condition and look for any signs of corrosion.

Hand Signal Chart

• Ensure the hand signal chart is displayed outside the cab and is legible.

Powerplant Inspection

Engine Condition

• Check the turbocharger, oil pressure, and blow-by for any issues.
• Verify the starting ability and inspect the exhaust system, guards, and insulation.
• Look for any oil leaks and check the air cleaner.

Hoses and Belts

• Inspect engine mounting hardware, hoses, and belts for signs of wear or damage.
• Check the block heater and operational condition of the engine.

Electrical System

Batteries and Wiring

• Check the dates on the batteries and inspect the wiring for any damage.
• Verify the condition of lights, alternator, starting system, and instrumentation.
• Test switches and backup/travel/swing alarms.

Cooling System

Radiator and Fan

• Inspect the radiator for leaks and check the fan, belt, and guards.

Fuel System

Operation and Components

• Check the operation of the fuel system, including lines, pump, and tank.
• Look for any leaks in the system.

Hydraulic System

Pumps and Valves

• Inspect hydraulic pumps, valves, reservoir, hoses, and pipes for any damage or leaks.
• Check the oil level and control valves.
• Verify the operational condition of the hydraulic system, including cylinders and solenoid valves.

Differential and Brakes

Differential Operation

• Check the operation of the differential, drive line, and planetaries.

Brake System

• Inspect the travel brakes, including drums, linings, service and park brake operation, hoses, and lines.

Car Body and Crawler Assembly

Car Body Condition

• Inspect the car body for any damage or wear.
• Check travel locks, steering clutches/dogs, chains, sprockets, track pads/pins, idlers, inter. rollers/tumblers, and side frames.

Carrier Frame

Welds and Metal Condition

• Check for any weld or metal cracks, distortion, or loose bolts.
• Inspect track wedges.

Outriggers/Assembly Jacks

Components and Condition

• Inspect outrigger boxes, beams, arms, cylinders, solenoid valves, pins, connections, floats, and holding valves.
• Check for any cracks or breaks in hoses and pipes.

Counterweight

Mounting and Decals

• Verify the mounting of the counterweight and check for warning decals.

Angle Indicator

Operational Condition

• Check the operational condition, serial number, and accuracy of the angle indicator.

Load Indicator

Operational Condition

• Verify the operational condition, serial number, and accuracy of the load indicator.

Wind Speed Indicator

Operational Condition

• Check the operational condition, serial number, and accuracy of the wind speed indicator.

Anti-Two Block System

Operational Condition

• Inspect the serial number and operational condition of the anti-two block system.

Main Load Block & Hook

Components and Condition

• Inspect the load block, sheaves, safety latch, hook, bearing, swivel, and reeving.
• Check for any damage or wear.

Headache Ball & Hook

Components and Condition

• Inspect the headache ball, sheaves, safety latch, hook, bearing, swivel, and reeving.
• Check for any damage or wear.

Wire Rope

Condition and Maintenance

• Inspect auxiliary hoist wire rope, main hoist wire rope, boom hoist wire rope, and pendants wire rope for damage, broken wires, and lubrication.
• Take pictures of the wire rope ends.

No Load Operational Test

Functionality Check

• Perform a no-load operational test to ensure all crane functions are working correctly.

Load Test

Main Hoist and Auxiliary/Jib Hoist

• Conduct a load test on the main hoist and auxiliary/jib hoist to ensure they can handle the rated capacity.
• Record the test weight, percent of capacity, and load test results.

Final Inspection and Documentation

Visual Inspection

• Take pictures of all sides of the machine.
• Record any notes or findings during the inspection.

Signature and Completion

• Sign off on the inspection checklist to confirm completion.
• Store the inspection records securely for future reference.

China Mobile Crane Daily Inspection Checklist Manufacturers …

Mobile Crane Daily Inspection Checklist: A Comprehensive Guide

Introduction

Conducting daily inspections of mobile cranes is crucial for ensuring the safety and functionality of the equipment. This guide outlines the key components and steps involved in a thorough mobile crane daily inspection.

Importance of Daily Inspections

Daily inspections help identify immediate problems that could impact safe operation, reducing the risk of accidents and ensuring compliance with regulatory standards such as OSHA.

Pre-Inspection Preparation

Before starting the inspection, ensure you have the necessary tools and documentation, including:
– The mobile crane’s operator manual
– Load charts
– Inspection checklist forms
– Pen or pencil for marking the checklist

Inspection Checklist Items

General Condition and Maintenance

Engine and Fuel

• Check the engine oil level and ensure it is at the recommended level[1][4][5].
• Verify the fuel level and ensure there is sufficient fuel for operation[1][4][5].

Coolant and Exhaust Systems

• Check the engine coolant level to prevent overheating[1][4].
• Ensure the level of exhaust gas after-treatment (e.g., ‘Ad Blue’) is adequate[4].

Fluid Levels and Leaks

• Check hydraulic fluid levels and ensure there are no leaks in the hydraulic systems[1][4].
• Visually inspect for fluid leaks in lines, tanks, hoses, valves, and pumps[1][4].

Air Systems

• Drain air tanks to prevent moisture buildup[1][4].

Safety and Warning Systems

Fire Extinguisher

• Ensure the fire extinguisher is accessible, adequately charged, properly sealed, and undamaged[1].

Alarms and Horns

• Verify that the reverse alarm, front, reverse, and swing horns are in working condition[1][2].

Lights and Indicators

• Check that all lights (headlights, tail lights, indicators) and windows are in good condition and functioning properly[1][2][4].

Tires and Tracks

• Inspect tires for damage (cuts, cracks, wear) and ensure correct pressure and tread depth[2][4].
• For crawler cranes, inspect tracks for damage and proper condition[3].

Control Mechanisms and Instruments

Operator’s Cab

• Check the condition of the cab glass, windscreen wipers, cab seating, seat belts, heating, and security systems[4].
• Ensure all controls, instruments, and load charts are functional and accessible[3][4].

Hydraulic and Electrical Systems

• Inspect hydraulic hoses, fittings, and tubing for signs of wear or malfunction[3][4].
• Check electrical components for signs of wear or malfunction to prevent unexpected shutdowns[3].

Lifting Mechanisms

Hoist Ropes and Wire Ropes

• Inspect hoist ropes for kinking, crushing, unstranding, birdcaging, or corrosion[1][3].
• Check wire ropes for broken wires, excessive wear, and external damage[3].

Hooks and Latches

• Perform a visual inspection of hooks and latches for cracks, deformation, and wear[1].

Boom and Jib

• Ensure the boom is in good condition without any damage, cracks, or smooth working issues[2][3].
• Check the jib for integrity and security[4].

Stability and Braking Systems

Outriggers

• Verify the proper function and visibility of outriggers to the operator, and ensure compliance with manufacturer specifications[3][4].

Braking System

• Check the braking system performance, including service brake, secondary emergency brake, and parking brake systems[3].

Additional Safety Checks

Load Indicating Systems

• Ensure load indicating, anti-two-block warning, and two-block damage prevention systems are operating correctly according to the manufacturer’s instructions[1].

Safety Latch and Hoist Limit Switch

• Verify that the safety latch and hoist limit switch are available and in working condition[2].

First Aid Kit and Reflective Tape

• Ensure a first aid kit is available in the operator cabin and is within the expiry date[2].
• Check that reflective tape is fixed at proper places[2].

Documentation and Sign-Off

Operator’s Sign-Off

• The operator must sign, enter their badge number, and date the inspection form after completing the checklist[1].

Foreman’s Review

• The foreman reviews the completed form, consults with the operator, and determines if the equipment is safe to operate. They must sign and date the form[1].

Repair Requests

• If deficiencies are identified, the responsible field superintendent reviews the form, checks the appropriate box, signs, and dates. Repairs must be completed and verified by the Construction Technical Integration Manager[1].

Conclusion

Daily inspections of mobile cranes are essential for maintaining safety and compliance. By following a comprehensive checklist, operators and supervisors can ensure that the crane is in a safe operating condition, reducing the risk of accidents and downtime. Regular inspections also help in adhering to regulatory requirements and maintaining the overall health of the equipment.

Procure inspection of cranes from China Leading inspection of …

Comprehensive Guide to Crane Inspections

Introduction

Crane inspections are crucial for ensuring the safety and efficiency of crane operations. These inspections help identify potential hazards, prevent accidents, and maintain the integrity of the crane. Here is a detailed guide on the types, procedures, and requirements for crane inspections.

Types of Crane Inspections

Initial Inspection

• Purpose: Conducted before the crane is put into use, especially for new or altered cranes.
• Scope:
• Review all new or altered crane components.
• Replace or repair any damaged parts.
• Test basic crane functions such as hoisting, lowering, trolley travel, and bridge travel.
• Perform a load test to ensure the crane can handle the intended loads[3][4][5].

Frequent Inspections

• Frequency: Daily to monthly intervals.
• Scope:
• Visual inspection before each shift to check for any deficiencies.
• Check control mechanisms, pressurized lines, hydraulic systems, hooks, latches, wire rope, electrical apparatus, tires, ground conditions, and cab windows.
• Inspect safety devices such as boom hoist limiting devices, luffing jib indicators, anti-two-block devices, and load moment indicators[1][3][5].

Periodic Inspections

• Frequency: Every 1 to 12 months, depending on usage and environment.
• Scope:
• Comprehensive inspection of all crane components.
• Check for deformed, cracked, or corroded members.
• Inspect loose bolts or rivets, sheaves, drums, and brake system parts.
• Evaluate load, wind, and other indicators over their full range.
• Inspect power plants, chains, hoses, fittings, and tubing.
• Test operational functions such as hoists, brakes, and limit switches[2][3][5].

Inspection Procedures

Pre-Inspection Preparation

• Review Past Records: Check previous inspection records to identify any recurring issues.
• Review Manual: Go through the crane’s manual to understand OSHA requirements and the intended functions of the crane.
• Operator Feedback: Discuss with the crane operator to understand any noticeable limitations or issues with the crane[2][4].

Visual Inspection

• Walk-Around: Conduct a visual inspection of the crane to check for any noticeable damage or wear.
• Check Major Components: Inspect the hook, boom, hydraulic system, control systems, tires, and brakes.
• Safety Devices: Check the condition and functionality of safety devices such as boom angle indicators and anti-two-block devices[1][2][5].

Functional Testing

• Operational Tests: Run tests to ensure the crane’s movements are functioning correctly, including telescoping, swinging, and hoisting.
• System Checks: Test the hydraulic system, electrical system, and brake system for any leaks, damage, or wear[2][3][5].

Detailed Inspection

• Disassembly: For yearly inspections, disassemble crane components to inspect thoroughly.
• Check for Wear and Tear: Inspect for signs of deformation, cracks, or corrosion on crane parts.
• Tighten Loose Parts: Tighten any loose bolts, screws, rivets, and other parts.
• Replace Damaged Parts: Replace any damaged or lost crane parts[1][3][5].

Documentation and Record Keeping

Importance of Documentation

• Compliance: Documentation helps in complying with OSHA regulations.
• Safety: Records help in tracking the condition of the crane and identifying potential hazards.
• Legal Protection: Documentation provides a paper trail in case of incidents or investigations[2][3][5].

What to Document

• Date of Inspection: Record the date the inspection took place.
• Inspector’s Details: Include the name and identification of the inspector.
• Findings and Actions: Document any findings and corrective actions taken.
• Retention: Keep the records for at least three months, though keeping all records indefinitely is recommended[2][3][5].

Inspector Qualifications and Responsibilities

Competent Person

• Designation: The employer must designate a competent person to perform the inspections.
• Qualifications: The inspector must be familiar with crane components and capable of identifying potential hazards.
• Authorization: The inspector must be authorized to take measures to eliminate any hazards found[1][3][5].

Inspector’s Role

• Conduct Inspections: Perform the inspections according to the scheduled intervals.
• Identify Hazards: Identify any potential hazards or deficiencies.
• Document Findings: Document the findings and any corrective actions taken.
• Ensure Compliance: Ensure that the crane operations comply with OSHA standards and manufacturer guidelines[1][3][5].

Additional Tips and Considerations

Manufacturer’s Instructions

• Follow Guidelines: Each crane has specific guidelines for inspection based on its design and use.
• Comprehensive Procedures: Follow procedures that are more comprehensive than the OSHA regulations if specified by the manufacturer[5].

Common Issues and Troubleshooting

• Damaged Cables: Check for fraying, kinking, or bird-caging. Ensure proper lubrication and correct spooling on the drum.
• Damaged Hooks: Use go/no-go gauges to check for deformation. Inspect for cracks using non-destructive testing methods.
• Misaligned Guide Troughs: Ensure the cable carrier is properly aligned within the guide trough to prevent premature wear[4].

Continuous Monitoring

• Regular Checks: Regularly check for visible signs of wear, damage, or deformation in critical components.
• Operational Testing: Test the crane’s operational systems regularly to ensure all safety devices are in working order[5].

By following these guidelines, crane operators and inspectors can ensure that cranes are operated safely and efficiently, reducing the risk of accidents and maintaining compliance with regulatory standards.

Crane third party inspection

Guide to Crane Third-Party Inspection Based on CTSTek Format

Introduction

Crane inspections are crucial for ensuring the safety and operational integrity of cranes. While the website http://www.ctstek.com/Crane-third-party-inspection/5043.html primarily focuses on pre-shipment inspections, the outlined checklist and inspection format can be adapted and expanded to provide a comprehensive guide for third-party crane inspections.

Pre-Inspection Preparation

Before conducting a third-party crane inspection, it is essential to prepare thoroughly:

Review Documentation

• Review the crane’s manual and past inspection records to understand its history, usage, and any previous issues.
• Familiarize yourself with OSHA regulations and the manufacturer’s guidelines for inspections.

Collaborate with Operators

• Have an open conversation with the crane operator to understand the crane’s usage and any noticeable limitations or issues.

Inspection Checklist

The inspection should be structured around several key areas, each with specific checks.

Aesthetic and Visual Inspection

• Base Stability: Check if the base of the crane wobbles. Place the crane on an inclined plane of 15 degrees to the horizontal and turn it to a position that results in tip-over to ensure stability.
• Surface and Coating: Perform a 3M tape adhesive test on the coating (painting/plating/screen printing, etc.) to ensure it is intact.

Structural Integrity

• Boom and Jib: Inspect the boom, jib, and attachments for cracks, corrosion, or any signs of wear.
• Mainframe: Examine the mainframe for any structural defects or damage.

Lifting Mechanisms

• Hooks and Latches: Inspect hooks for deformation or cracks and ensure latches are functioning properly.
• Wire Ropes: Check wire ropes for broken wires, excessive wear, or external damage.
• Hoist Chains: Inspect hoist chains, including end connections, for excessive wear, twist, distorted links, or stretch beyond manufacturer’s recommendations.

Hydraulic and Electrical Systems

• Hydraulic System: Check hoses, fittings, and tubing for signs of wear or malfunction. Ensure there are no leaks, damage, or clogs in the lines.
• Electrical System: Perform a Hi-Pot test (1500V 0.5 mA 3S) and an Earth Continuity Test (maximum 0.5 Ohm) to ensure electrical safety and integrity.

Control and Safety Systems

• Control Mechanisms: Check all controls in the cab to ensure they are responsive and functioning properly.
• Safety Devices: Test limit switches, locking and clamping devices, and other safety devices to ensure they are in working order.

Braking and Stability Systems

• Braking System: Inspect the service brake system, secondary emergency brake system, parking brake system (for rubber-tired cranes), or brakes/locking devices (for crawler cranes) to ensure they function properly and meet grade requirements.
• Outriggers: Verify outrigger functionality, visibility to the operator, and compliance with manufacturer specifications.

Functional Testing

• Operational Functions: Test the crane’s operational systems, such as hoists, brakes, and limit switches, to ensure everything is functioning properly.
• Load Testing: Perform a load test to ensure the crane can handle its rated capacity safely.

Documentation and Reporting

Record Keeping

• Document all inspection findings, including any issues or irregularities. This documentation should include the items checked, their results, and the name and signature of the person who conducted the inspection.
• Retain inspection records for a minimum period as required by OSHA regulations.

Certification

• For annual or comprehensive inspections, ensure that the crane is certified by a competent third-party inspector. This is particularly important for high-risk jobs or those involving public or government contracts.

Additional Considerations

Manufacturer’s Instructions

• Review and follow the manufacturer’s specific guidelines for inspection, as these may include additional or more comprehensive requirements than OSHA standards.

Environmental and Site Conditions

• Check ground conditions and ensure the crane is set up correctly according to site restrictions and operational factors such as load capacity and center of gravity.

Conclusion

A thorough third-party crane inspection is critical for ensuring the safety and reliability of the crane. By following a structured checklist that includes aesthetic, visual, structural, and functional inspections, you can identify potential issues before they become safety hazards. Proper documentation and adherence to OSHA regulations and manufacturer guidelines are also essential components of a comprehensive inspection process.

Crane Inspections and Inspections of Hoisting and Lifting …

Comprehensive Guide to Crane, Hoisting, and Lifting Equipment Inspections

Introduction

Ensuring the safety, reliability, and compliance of crane, hoisting, and lifting equipment is crucial for any operation that involves these devices. This guide outlines the key aspects of these inspections, the services provided, and the benefits of engaging a professional inspection company.

Why Conduct Crane, Hoisting, and Lifting Equipment Inspections?

Crane, hoisting, and lifting equipment inspections are essential to:
– Meet Regulatory Requirements: Ensure compliance with all applicable regulations, standards, and engineering practices.
– Ensure Safety: Assure the safe and proper working capability and condition of the equipment.
– Maintain Equipment: Maintain the capability and availability of the equipment.
– Maximize Uptime: Minimize operational impact by maximizing uptime and planning outages.

Types of Equipment Inspected

Inspections cover a wide range of equipment, including:

Material-Handling Devices

• Cranes
• Derricks
• Fork-lifts
• Truck-mounted cranes
• Shackles
• Hooks
• Elevating platforms
• Telehandlers

Personnel Handling Devices

• Elevators
• Escalators
• Ski lifts
• Cable cars
• Mobile elevating work platforms (MEWPs)

Inspection Services

Detailed Inspection Components

Inspection services include:

Mechanical and Structural Inspections

• Checking of brakes, clutches, sheaves, and wire rope assemblies
• Inspection of all structural load-bearing members, including sheaves
• Checking crane girders, rails, and columns of overhead cranes to assure structural integrity

Load Testing

• Dynamic and static load testing

Non-Destructive Testing (NDT)

• NDT of load hooks for cracks and visual inspections for distortions

Operational Tests

• Operational tests to ensure the unit is functioning properly

Periodic Inspections

• Periodic inspections and inspections prior to use of mechanical, structural, electrical, and safety systems
• Inspections of wire ropes and chains

Safety Devices

• Re-examination of all safety devices

Regulatory Compliance

• Regulatory compliance assessments

Additional Services

• Design studies and calculation reviews
• Line level and span crane gantry surveys
• Remnant life assessment
• Repairs supervision

Benefits of Professional Inspections

Compliance and Safety

• Ensure that all equipment complies with statutory requirements and international standards.
• Enhance safety by identifying and addressing potential hazards before they become critical issues.

Reliability and Uptime

• Maintain the operational integrity of the equipment, reducing downtime and increasing overall efficiency.
• Plan outages and maintenance to minimize operational impact.

Training and Support

• Provide training for operators of cranes and elevating platforms in accordance with local and international standards.
• Offer supervision for repairs to ensure that any necessary work is done correctly.

Choosing the Right Inspection Service

When selecting an inspection service, consider the following:

Expertise and Experience

• Look for companies with extensive experience and expertise in crane, hoisting, and lifting equipment inspections.

Global Reach and Accreditation

• Ensure the company is accredited to perform conformity assessments and statutory inspections globally.

Comprehensive Inspection Reports

• The service should provide detailed inspection reports, including photos, videos, and a checklist of all inspected components.

Conclusion

Crane, hoisting, and lifting equipment inspections are critical for ensuring safety, compliance, and reliability. By engaging a professional inspection service, you can maintain the integrity of your equipment, minimize downtime, and ensure regulatory compliance. This guide provides a comprehensive overview of the services and benefits associated with these inspections, helping you make informed decisions about your equipment’s maintenance and operation.

Crane Inspection Checklist – Fill Online, Printable, Fillable …

Comprehensive Guide to Crane Inspection Checklists

Introduction

Crane inspections are crucial for ensuring the safety and efficiency of crane operations. These inspections help identify potential hazards, prevent accidents, and comply with regulatory requirements. Here is a detailed guide outlining the key aspects of crane inspection checklists.

Types of Crane Inspections

Frequent Inspections

Frequent inspections are conducted on a daily to monthly basis and are essential for maintaining the immediate safety and functionality of the crane.

Daily Inspections

• Maladjustments and Interference: Check for any maladjustments that could interfere with the proper operation of the crane[1][3][5].
• Hydraulic and Air Systems: Inspect for deterioration or leakage in lines, tanks, valves, drain pumps, and other parts of air or hydraulic systems[1][2][5].
• Hooks and Latches: Visual inspection for cracks, deformation, and wear on hooks and latches[2][5].
• Hoist Chains and Ropes: Check for deformities, wear, twist, or distortion in hoist chains and ropes[1][4][5].
• Control Mechanisms: Ensure all control mechanisms are functioning correctly and not maladjusted[2][5].
• Tires and Tracks: Inspect tires or tracks for damage or excessive wear[2][5].
• Safety Devices: Check load indicating, anti-two-block warning, and two-block damage prevention systems[2].

Monthly Inspections

• Additional Checks: Along with daily checks, perform a more thorough inspection of components such as sheaves, drums, pins, shafts, gears, bearings, and rollers[1][4].

Periodic Inspections

Periodic inspections are more comprehensive and are typically performed on an annual basis or as required by specific conditions.

Annual/Comprehensive Inspections

• Structural Integrity: Inspect for deformed, cracked, or corroded members[1][4].
• Bolts and Rivets: Check for loose bolts or rivets[1][4].
• Brake and Clutch Systems: Inspect for excessive wear on brake and clutch system parts, linings, pawls, and ratchets[1][4].
• Indicators: Verify the accuracy of load, wind, and other indicators[1][4].
• Power Plant: Check for faulty or unsafe powerplants, including leaking exhaust and emergency shut-down features[1][4].
• Electrical Apparatus: Inspect for pitting or other deterioration of controller contactors, limit switches, and pushbutton stations[1][4].
• Tires: Inspect tires for damage or excessive wear[1][4].

Specific Inspection Items

Controls and Operating Mechanisms

• Ensure all controls and operating mechanisms are properly adjusted and free from excessive wear[4][5].

Hydraulic and Air Systems

• Check for any deterioration or leakage in lines, tanks, valves, drain pumps, and other parts of air or hydraulic systems[1][2][5].

Hooks and Latches

• Inspect hooks for bending, spreading, cracks, and ensure safety latches are in good condition[2][5].

Hoist Chains and Ropes

• Check for excessive wear, twist, stretch, kinks, or broken wires in hoist chains and ropes[1][4][5].

Safety Devices

• Verify the proper operation of safety devices such as upper limit switches, brake systems, and load indicating systems[2][5].

Tires and Tracks

• Inspect tires or tracks for damage or excessive wear and ensure proper inflation[2][5].

Outriggers and Foundation

• Check the locking devices and general condition of outriggers and ensure the foundation and cribbing are secure[4].

Fire Extinguisher

• Ensure the fire extinguisher is accessible, adequately charged, properly sealed, and undamaged[2].

Lubrication

• Check for leaks or excess grease in moving crane parts and ensure proper lubrication levels[5].

Boom and Crane Structure

• Inspect for bent or twisted parts, broken welds, cracks, and heavy rust on the boom and crane structure[4].

Inspection Procedures

Pre-Use Inspection

• The equipment operator must perform a visual inspection of the crane before each use and report any deficiencies to the foreman[2].
• Complete a checklist that includes items such as engine oil level, fuel level, belts, water hoses, tires, reverse alarm, fire extinguisher, engine coolant level, brake operation, and all control mechanisms[2].

Documentation

• Maintain a certification record with the inspector’s signature and date for monthly inspections[1].
• Document all inspections, including daily, monthly, and annual checks, and keep records of any repairs or adjustments made[3][4].

Qualified and Competent Inspectors

• Inspections must be performed by a qualified and competent person who has the necessary knowledge, training, and experience to identify and address hazards[3].

Special Conditions

Post-Assembly

• Inspect the crane after assembly to ensure all components are properly installed and functioning correctly[3].

Modified or Repaired Equipment

• Inspect the crane after any modifications or repairs to ensure it is safe to operate[3].

Standby Cranes

• Inspect cranes that are not used on a regular basis and standby cranes at least semi-annually[4].

Common Safety Hazards

Unlevel Cranes

• Ensure the crane is level to prevent it from falling over or causing structural damage to the boom or mast[3].

Structural Damage

• Inspect for any structural damage to the boom or mast, which can cause it to buckle[3].

Unstable Ground Conditions

• Be cautious of unstable ground conditions, especially in poor weather, to prevent the crane from tipping or driving off the edge[3].

By following these detailed inspection checklists and procedures, operators and employers can significantly reduce the risk of accidents, ensure compliance with safety regulations, and maintain the operational integrity of the crane.

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Guide to Periodic Crane Inspections

Introduction

Periodic crane inspections are crucial for ensuring the safety, efficiency, and longevity of crane operations. These inspections are mandated by regulatory bodies such as OSHA and are essential for identifying and addressing potential hazards before they become critical.

Types of Crane Inspections

Initial Inspections

Initial inspections are required for new cranes, as well as for cranes that have been altered, modified, or repaired. These inspections must be conducted by a qualified individual to ensure that the crane meets the manufacturer’s criteria and complies with safety standards. Any deficiencies identified during these inspections must be documented and addressed before the crane is put into service.

Frequent Inspections

Frequent inspections are less comprehensive than initial inspections but are equally critical. They are performed at intervals ranging from daily to monthly, depending on the crane’s usage and service class.

Daily to Weekly Inspections

• These inspections focus on the day-to-day operating mechanisms.
• Key areas to check include:
• Functional operating mechanisms for maladjustments or excessive wear.
• Air and hydraulic systems for deterioration or leakage.
• Hooks for deformation or cracks.
• Hoist chains for excessive wear, twist, or stretch beyond manufacturer recommendations.
• Rope reeving to ensure compliance with manufacturer recommendations[1][3][5].

Monthly Inspections

• These inspections are more detailed and include checks on:
• Control mechanisms.
• Pressurized lines.
• Hydraulic system.
• Hooks and latches.
• Wire rope and reeving.
• Electrical apparatus.
• Ground conditions and other safety-critical components[4][5].

Periodic Inspections

Periodic inspections are more thorough and are conducted at intervals ranging from 1 to 12 months, depending on the crane’s activity, severity of service, and work environment.

Annual Inspections

• These inspections are comprehensive and may require disassembly of certain components.
• Key areas to check include:
• Overall wear on parts like sheaves, rivets, sprockets, and brakes.
• Deformed, cracked, or corroded members.
• Loose bolts or rivets.
• Worn, cracked, or distorted components such as pins, bearings, shafts, gears, rollers, and locking devices.
• Excessive wear on brake system parts, linings, pawls, and ratchets.
• Load, wind, and other indicators for significant inaccuracies.
• Electrical components and wiring for pitting or deterioration[1][3][5].

Quarterly Inspections for Severe Service

• Cranes in severe service conditions may require more frequent inspections, such as quarterly checks, to ensure safety and prevent wear.
• These inspections cover similar areas as annual inspections but are more frequent due to the intense usage[2][3].

Who Should Perform Crane Inspections?

Crane inspections must be performed by a competent individual who is capable of identifying hazards and authorized to take corrective measures. This can be a qualified employee appointed by the employer or a professional from a third-party inspection company. Only OSHA-certified inspectors can conduct the necessary crane inspections outlined by OSHA standards[1][2][4].

Developing an Effective Inspection Schedule

Factors Influencing Inspection Frequency

• Usage: Cranes used extensively need more frequent inspections than those used rarely.
• Service Class: Cranes classified under heavy or severe service require more frequent inspections than those under normal service.
• Components: Higher capacity cranes and those performing complex activities need more frequent inspections.
• Age: Older cranes with more extensive wear should be inspected more often than newer cranes.
• Downtime: Cranes with longer downtime for repairs should be inspected more frequently upon return to service.
• Impact on Operations: Critical cranes should be inspected more often to ensure continuous operation[2][3][5].

Special Considerations

• Idle Cranes: Cranes that have been idle for more than six months require both frequent and periodic inspections before returning to service.
• Relocation and Modifications: Cranes must be inspected before and after relocation, and after any additions, alterations, or upgrades[1][3][4].

Importance of Documentation

Documentation is crucial for maintaining a record of inspections and ensuring compliance with OSHA standards.
– Monthly Inspections: Documentation is required and must include the items checked, the results, and the name and signature of the person who conducted the inspection. Records must be retained for at least three months[4][5].
– Annual Inspections: Documentation must be signed by the person who conducted the inspection and retained for a minimum of 12 months[5].

Conclusion

Periodic crane inspections are vital for maintaining the safety and efficiency of crane operations. By understanding the types of inspections, the frequency at which they should be performed, and who should conduct them, operators can ensure compliance with regulatory standards and prevent potential hazards. Regular inspections not only extend the life of the crane but also reduce downtime and enhance overall operational safety.

Free Crane Inspection Checklist | PDF

Comprehensive Guide to Crane Safety Checklists

Introduction

Crane safety is paramount in construction and industrial settings to prevent accidents, ensure compliance with regulations, and maintain efficient operations. A thorough crane safety checklist is essential for identifying potential hazards and ensuring that all safety protocols are followed.

Types of Crane Inspections

Initial Inspections

• Conducted for new cranes, reinstalled cranes, or those that have undergone significant modifications.
• Ensure the crane meets all safety standards and operates as intended before any lifting tasks begin.
• Include a thorough examination of all components, operational tests, and a review of manufacturer’s instructions and maintenance records[2].

Daily Inspections

• Performed by the crane operator at the start of each shift.
• Focus on readily visible components for signs of damage or wear.
• Check for:
• Leaks
• Loose parts
• Malfunctions in the crane’s control systems
• Control mechanisms
• Pressurized lines
• Hydraulic system
• Hooks and latches
• Wire rope and reeving
• Electrical apparatus
• Tires
• Ground conditions
• Cab windows
• Safety devices[3].

Monthly Inspections

• Include functional tests and inspections of additional components not covered in daily checks.
• Check:
• Boom and jib
• Sheaves and drums
• Pins, bearings, shafts, gears, rollers, and locking devices
• Brake and clutch system
• Safety devices
• Power plants
• Chains
• Hoses, fittings, and tubing
• Pumps and motors
• Hydraulic and pneumatic valves and cylinders
• Outrigger or stabilizer pads/floats
• Electrical components and wiring
• Warning labels
• Operator seat
• Steps, ladders, handrails, and guards[3].

Annual/Comprehensive Inspections

• Conducted at least once a year.
• Include all components inspected in monthly checks plus:
• Turntable and tower bolts for proper condition and torque (for tower cranes)
• Detailed inspection of wire ropes, hooks, and structural elements for signs of wear, damage, or deformation
• Operational testing of hoists, brakes, and limit switches
• Review of maintenance records and manufacturer’s instructions[3].

Key Components to Inspect

Crane Structure and Components

• Boom and Jib:
• Check for cracks, corrosion, tight bolts and rivets, and documented certification if boom members have been repaired[2].
• Sheaves and Drums:
• Inspect for smooth grooves, no cracks, proper flange condition, and minimum wrap requirements on the drum[2].
• Hooks and Hook Blocks:
• Ensure they are labeled with rated capacity, counterweighted, and free of cracks or excessive wear. Hooks used for personnel lifting must have effective safety catches[2].
• Wire Rope:
• Inspect for broken wires, excessive wear, and external damage. Check for visible signs of wear or damage, such as kinks, cuts, breaks, corrosion, or reduced diameter[2][4].

Safety Devices and Operational Aids

• Boom Angle Indicator and Boom Hoist Disconnect:
• Ensure these are readable from the operator’s station for accurate control and to shut off or stop the boom hoist at designated angles[2].
• Two-Blocking Devices and Power-Controlled Lowering:
• Required for telescoping booms and cranes lifting personnel to ensure safe operation and prevent malfunctions[2].
• Leveling Indicating Device:
• Ensure the crane is level for safe operation[2].
• Braking System:
• Assess the service brake system, secondary emergency brake system, parking brake system (for rubber-tired cranes), or brakes/locking devices (for crawler cranes) to ensure they function properly and meet grade requirements[2].

Ground Conditions and Setup

• Ground Conditions:
• Determine the adequacy of ground conditions beneath the equipment set-up area, including support/foundation, matting, cribbing, blocking, etc.[1].
• Outriggers:
• Verify proper function, visibility to the operator, and compliance with manufacturer specifications[2].

Operator Qualifications and Training

Operator Certification

• Ensure the crane operator possesses a valid certification to perform lifts[5].
• Verify operator qualifications and training through interviews and observation to determine competence in operating the equipment safely[1].

Signal Person Qualifications

• Verify the qualifications and documentation of the signal person. Acceptable documents include both physical and electronic records[1].
• Ensure the communication system used by the crane operator and the signal person is the one specified on the signal person’s qualification documentation[1].

Power Line Safety and Other Hazards

Overhead Power Lines

• When overhead power lines are on the construction site, verify that the utility owner/operator was contacted and if the lines are energized. Obtain the voltage of the power lines (if known)[1].
• Ensure a work zone around the crane is demarcated and encroachment prevention steps are being used[1].

Load Handling and Lift Plans

• Verify that lift plans are being followed. Lift plans should outline how loads will be lifted, identify potential hazards, and provide an overview of traffic control measures[5].
• Ensure the weight of the load(s) is within the capacity of the equipment or below 75% of capacity if a load moment indicator was used[1].

Documentation and Compliance

Maintenance and Inspection Records

• Ensure all inspections, tests, repairs, modifications, and maintenance are documented clearly in the maintenance logbook and kept with the crane[4].
• Verify that the equipment and wire rope inspection requirements have been met and that the documentation is available for all inspections[1].

Compliance with OSHA Regulations

• Ensure compliance with OSHA regulations, including those related to inspections (1926.1412), signal person qualifications (1926.1428), power line safety (1926.1408), and operator qualification & certification (1926.1427)[3].

Conclusion

A comprehensive crane safety checklist is crucial for ensuring the safe operation of cranes in various settings. By conducting regular inspections, verifying operator qualifications, ensuring compliance with regulations, and checking key components, you can significantly reduce the risk of accidents and maintain a safe working environment. Always follow manufacturer instructions, document findings, and address any issues promptly to uphold the highest standards of crane safety.

Crane Inspection Requirements [With Checklists]

Comprehensive Guide to Crane Inspections

Overview of Crane Inspection Requirements

Crane inspections are crucial for ensuring the safety and proper functioning of crane equipment. These inspections are governed by OSHA standards, which differentiate between several types of inspections.

Types of Crane Inspections

Initial Inspection

• Purpose: Conducted before the crane is put into use for the first time.
• Scope: Includes new cranes, altered cranes, and used cranes that have undergone significant changes.
• Steps:
• Review all new or altered cranes before their first use.
• Replace or repair any damaged crane parts.
• Check crane functions such as hoisting, lowering, trolley travel, bridge travel, limit switches, and locking and safety devices.
• Perform a load test to ensure the crane operates correctly under load.

Frequent Inspection

• Frequency: Daily to monthly intervals.
• Scope: Focuses on identifying defects or issues during operation hours and between regularly scheduled inspections.
• Steps:
• Check all functional operating mechanisms to ensure no maladjustment that could interfere with proper operation.
• Inspect all parts of air and hydraulic systems for deterioration or leakage.
• Examine hooks for deformation or cracks.
• Inspect hoist chains, including end connections, for excessive wear, twist, distorted links, or stretch beyond manufacturer’s recommendations.
• Verify that the wire rope reeving system complies with the manufacturer’s recommendations.
• Check the condition of tires and ensure the brake system is operational.

Periodic Inspection

• Frequency: 1 to 12 months, depending on the crane’s activity, severity of service, and work environment.
• Scope: A comprehensive inspection to identify and address any potential safety hazards.
• Steps:
• Inspect for deformed, cracked, or corroded members.
• Check for loose bolts or rivets; cracked or worn sheaves and drums; and worn, cracked, or distorted components like pins, bearings, shafts, gears, rollers, and locking and clamping devices.
• Evaluate excessive wear on brake system parts, linings, pawls, and ratchets.
• Check load, wind, and other indicators over their full range to catch significant inaccuracies.
• Inspect for excessive wear of chain drive sprockets and excessive chain stretch.
• Check the power plant for noncompliance with applicable safety requirements.
• Inspect electrical apparatus for pitting or other deterioration of parts like controller contactors, limit switches, and push-button stations.

Conducting a Crane Safety Inspection

Role of the Inspector

• The inspection must be performed by a “competent individual” who is familiar with crane components and capable of identifying potential hazards. This person must also be authorized to take measures to eliminate those hazards if found[4].

Functional Test of the Equipment

• Before use, a functional test must be conducted to evaluate how the crane works and ensure it is operating normally. This includes testing all critical crane components such as the control system, braking system, power plant, and load-sustaining structural components like the hoisting equipment[4].

Detailed Inspection Checklist

Daily Inspection

• Control and Drive Mechanisms:
• Check for wear and tear.
• Air and Hydraulic Lines:
• Look for any leakage.
• Hydraulic System:
• Determine the right fluid level.
• Hooks, Latches, and Wire Rope:
• Identify any wear and tear.
• Tires:
• Check for damage or excessive wear.
• Crane Operator’s Cab:
• Assess cracks on windows.
• Rails and Supporting Surfaces:
• Check for any loose rails and supporting surfaces[2].

Monthly Inspection

• Conduct the same procedure as the daily inspection in a more detailed manner.
• The employer must document the inspection in detail, including the name of the inspector and the date of inspection. These records must be kept for at least three months[2].

Yearly Inspection

• This is a comprehensive inspection that may require disassembly of the crane components.
• Steps:
• Thoroughly inspect the crane structure, including the jib.
• Look for signs of deformations, cracks, or corrosion of crane parts.
• Tighten loose bolts, screws, rivets, and other parts.
• Replace any damaged or lost crane parts.
• Check drums and sheaves for wear and tear.
• Inspect operator control systems and chains for wear and tear.
• Ensure all other crane components are in good condition and make necessary fixtures[2].

Record Keeping and Documentation

• Thorough documentation is essential for tracking the operation of the crane and creating a paper trail for future reference.
• Required Information:
• Date of the inspection.
• Name and identification of the inspector.
• Findings from the inspection.
• Corrective actions taken to address any issues[3].

Pre-Inspection and Collaboration

• Review Past Records:
• Inspectors should review past records of inspections to check for any past issues and understand the overall status of the crane.
• Review the Manual:
• Review the crane manual to double-check OSHA requirements and the intended functions of the crane.
• Collaborate with the Operator:
• Have an open conversation with the crane operator to understand the crane’s usage and any noticeable limitations or issues[3].

Common Issues and Troubleshooting

• Damaged Cables:
• Check for fraying, kinking, or bird-caging.
• Ensure proper lubrication and correct spooling on the drum.
• Confirm the cable is the correct size and construction for the application.
• Damaged Hooks:
• Look for deformities or cracks daily.
• Use go/no-go gauges to check for deformation.
• Inspect for cracks using non-destructive testing methods.
• Verify that safety latches are present and functioning[5].

Additional Tips for Crane Inspections

• Inspect Guide Trough for Misalignment:
• Ensure the cable carrier is properly aligned within the trough to prevent premature wear and failure.
• Check for Missing Crossbars & Fasteners:
• Note any missing crossbars or fasteners, as these can cause system failure. Address these issues immediately[5].

By following these guidelines and conducting regular, thorough inspections, you can ensure the safe and efficient operation of your crane equipment, protecting both the operators and the surrounding environment.

Frequently Asked Questions (FAQs)

What are the key components to include in a crane inspection checklist?

A comprehensive crane inspection checklist should cover several critical areas to ensure the crane’s safe and efficient operation. This includes a visual inspection of the crane’s structural components such as the boom, mast, jib, and outriggers to identify any signs of damage, wear, or corrosion. The checklist should also involve a functional inspection to test the crane’s various functions, including hoisting, lowering, slewing, and traveling, and to verify that the crane operates within the specified load capacity and speed limits. Additionally, it is essential to inspect wire ropes for signs of wear, broken strands, or kinks, and to check safety components such as hooks, slings, shackles, and lifting accessories for any cracks, deformations, or excessive wear. The inspection should also include non-destructive testing (NDT) techniques like magnetic particle testing, ultrasonic testing, and radiographic testing to detect hidden defects.

How often should crane inspections be conducted?

Crane inspections should be conducted at regular intervals to ensure ongoing safety and compliance. Annual inspections are mandatory and involve a thorough examination of the crane’s structure, components, and systems by certified crane inspectors. These inspections are more comprehensive and cover all aspects of the crane to ensure compliance with safety standards and regulations. In addition to annual inspections, periodic inspections may be required, such as monthly or quarterly checks, depending on the usage and environment of the crane. These periodic inspections help in identifying and addressing potential issues before they become major problems.

What role do manufacturer specifications play in crane inspections?

Manufacturer specifications are crucial in crane inspections as they provide the necessary guidelines and standards that the crane must adhere to for safe and efficient operation. Before conducting an inspection, it is essential to familiarize yourself with the reference specifications of the crane model, which include information on load capacity, hoisting speed, trolley speed, lifting height, and other essential parameters. These specifications help inspectors ensure that the crane meets all the required standards and that any repairs or adjustments are made in accordance with the manufacturer’s recommendations.

What are the different types of testing involved in crane inspections?

Crane inspections involve several types of testing to evaluate the crane’s condition and performance. Load testing is used to apply additional weight to the crane to assess its capacity and performance under maximum load conditions. This helps in identifying any structural or functional issues that need timely repairs or adjustments. Non-destructive testing (NDT) techniques such as magnetic particle testing, ultrasonic testing, and radiographic testing are used to inspect critical crane components like welds, bolts, and structural elements without causing any damage. Additionally, functional testing involves checking the operation of the crane’s various mechanisms, including the boom hoist, load hoist, telescoping boom, and swing mechanism, to ensure they are functioning correctly.

Why is it important to use qualified inspectors for crane inspections?

Using highly qualified inspectors is essential for maintaining the integrity and accuracy of crane inspection results. Qualified inspectors have the necessary expertise and experience to conduct inspections systematically and precisely, ensuring that all critical components are evaluated thoroughly. They are familiar with the latest international standards and practices, which helps in identifying potential hazards and ensuring compliance with regulatory requirements. This ensures not only the quality of the equipment but also the safety of the workers operating the crane, preventing accidents and damage to property.