Overhead Cranes and Hoists SPP# 1910.
179A
Quick Reference
1.0 Purpose.......................................................................................................................................... 2
2.0 Scope and Applicability ............................................................................................................... 2
3.0 Reference....................................................................................................................................... 2
4.0 Policy ............................................................................................................................................. 2
5.0 General Responsibilities .............................................................................................................. 2
6.0 Procedure ...................................................................................................................................... 2
6.1 Definitions ........................................................................................................................ 3
6.2 General Provisions .......................................................................................................... 4
6.2.1 Construction, Installation and Marking ............................................................ 4
6.2.2 Inspection of overhead cranes and hoist ......................................................... 4
6.2.2.1 Training of Inspection Personnel ................................................. 4
6.2.2.2 Pre-Use inspection ........................................................................ 5
6.2.2.3 Frequent (Monthly) inspection...................................................... 5
6.2.2.4 Periodic (Annual) inspection ........................................................ 5
6.2.2.5 Load Testing................................................................................... 6
6.2.3 General Operation and Use.............................................................................. ..6
6.2.3.1 Training of Operators ................................................................... .6
6.2.3.2 Hoisting Practices ........................................................................ . 7
6.2.3.3 Handling the load..............................................................….......... 7
6.2.3.4 Lockout/Tagout of overhead crane/hoist..................................... 7
6.3 Specific Responsibilities.......................................................................................... .......8
6.3.1 Managers/Unit Heads ......................................................................................... .8
6.3.2 County Maintenance Engineers, Bridge Maintenance Supervisors,
Equipment Sub- shop Supervisors, Ferry Superintendents, Rail
Operations Manager .. 8
6.3.3 Qualified Person ................................................................................................. 8
6.3.4 Supervisors ........................................................................................................ 8
6.3.5 Employees .......................................................................................................... 8
6.3.6 Safety Engineers ................................................................................................ 9
6.3.7 Safety and Loss Control ................................................................................... 9
6.3.8 Central Equipment Unit and Division Equipment ....................................... .... 9
Appendix A: Types of overhead cranes/hoists ....................................................................... 10
Appendix B: Inspection Forms ................................................................................................. 13
1.0 Purpose
The purpose of this safety policy and procedure is to ensure all overhead cranes and
hoists used by North Carolina Department of Transportation (NCDOT) employees are
installed, inspected, maintained and operated in a safe manner.
2.0 Scope and Applicability
This safety policy and procedure applies to overhead cranes and hoists, including, top
running or underhung bridge cranes, monorail cranes, fixed hoist and others having
the fundamental characteristics of a hoisting mechanism attached to a movable bridge
or trolley and traveling on an overhead runway structure or fixed structure to move
loads.
This safety policy and procedure details the areas of responsibility for managers/unit
heads, County Maintenance Engineer, qualified persons, supervisors, employees,
Safety Engineers, and the Central Equipment Unit within NCDOT.
3.0 Reference
This safety policy and procedure is established in accordance with OSHA 29 CFR
1910.179, Overhead Cranes and the ANSI/ASME B.30 series.
4.0 Policy
It is the policy of NCDOT to provide a place of employment that is free from
recognized hazards that cause or are likely to cause death or serious physical harm
to employees or the public. All overhead cranes and hoists covered by the scope of
this policy and procedure shall be properly installed, inspected, maintained and
operated in a safe manner.
5.0 General Responsibilities
It is the responsibility of each manager/unit head, supervisor, and employee to
ensure implementation of NCDOT's safety policy and procedure on overhead cranes
and hoists. It is also the responsibility of each NCDOT employee to immediately
report any unsafe act or condition to his or her supervisor. Specific responsibilities
are found in Section 6.3.
6.0 Procedure
This section provides applicable definitions, establishes general provisions, and
identifies specific requirements required by NCDOT's safety policy and procedure
for overhead cranes and hoists.
6.1. Definitions
Crane
A machine for lifting and lowering a load and moving it horizontally, with the
hoisting mechanism an integral part of the machine.
Overhead crane
A crane with a movable bridge carrying a movable or fixed hoisting mechanism and
traveling on an overhead fixed runway structure
Wall crane
A crane having a jib with or without trolley and supported from a sidewall or line of
columns of a building. It is a traveling type and operates on a runway attached to
the sidewall or columns.
Monorail Crane
A crane having a hoist attached to a trolley that moves either on the top or bottom
flange of a beam runway.
Bridge Girder
A crane member, on which trolleys travel horizontally, mounted between and
supported by trolleys or end trucks.
Hoist
An apparatus that lifts or lowers a load. It can be installed in a fixed location or on an
overhead trolley.
Hoist chain
The load bearing chain.
Qualified person
A person who, by possession of a recognized degree in an applicable field or
certificate of professional standing, or by extensive knowledge, training, and
experience has successful demonstrated the ability to solve problems relating to
the subject matter at hand.
Rated Load
The maximum load for which a crane or individual hoist is designed and built
by the manufacturer and shown on the equipment nameplate(s).
Frequent Inspection
A monthly inspection at a minimum.
Periodic Inspection
An annual inspection at a minimum.
6.2. General Provisions
This section details the provisions of this safety policy and procedure with each provision
discussed in a separate subsection. These provisions are:
o Construction, Installation and Marking
o Inspection of Overhead cranes and Hoists
o General Operation and Use
6.2.1. Construction, Installation and Marking
Overhead cranes and hoists shall be constructed using hoists, and trolleys, meeting the
guidelines of OSHA 1910.179 and the ANSI/ASME B.30 series.
Overhead crane runways and supporting structures shall be designed, constructed and
installed to withstand the loads and forces imposed by the crane. A qualified person familiar
with structural loading shall review the support structure holding the overhead crane/hoist
prior to load testing.
The overhead crane and/or hoist load rating shall be marked on each side of the girder
holding the overhead crane or hoist and shall be visible from the ground. The load rating
shall be marked on the trolley, hoist, load block, and hook. The initial load test will be
125% of the desired rating. For additional load test information see Section
6.2.2.5 Load Testing.
6.2.2. Inspection of overhead cranes and hoist
Documentation
All inspection forms will be filed by hoist number and be available for auditing/inspection as
required.
Any overhead crane or hoist that does not have documented proof or has not been inspected
as outlined in this Safety Policy and Procedure since its initial installation, must be taken
down and inspected to ensure that the overhead crane/hoist is within manufacturer/factory
specifications.
6.2.2.1. Training of Inspection Personnel
Employees inspecting and maintaining overhead cranes and hoists shall receive
training specific to the type of inspection they will perform i.e. pre- use, frequent,
periodic inspection, load testing, and maintenance.
This training shall be completed before an employee begins inspecting an overhead
crane. It is recommended that re-training occur every three years or when equipment
or job conditions change. Re-training should also occur if there is an indication or
incident that suggests lack of knowledge or skill.
A qualified person shall conduct or direct this training.
6.2.2.2 Pre-use inspection
Each overhead crane or hoist shall be given a pre-operational inspection. At a
minimum this inspection shall include a visual inspection of the hook for safety latch,
cracks, bends or twists, and overhead crane/hoist operation that is smooth with no
unusual sounds. This inspection does not need to be documented.
6.2.2.3 Frequent (Monthly) Inspection
Each overhead crane/hoist shall be given a frequent inspection. At a minimum, this
inspection shall be conducted monthly and include a visual examination of the
following areas:
• Operating controls
• Trolley and bridge
• Beams for damage
• Power supply
• Chain limit switch
• Hook for deformation and safety latch
• Proper lubrication
This inspection shall be documented on NC DOT Overhead Hoist Inspection
“Frequent” Form CC-39. (See Appendix B: Inspection Forms)
Note: Some hoists are only used seasonally and only need inspection when in use.
When used seasonally, it is recommended that overhead cranes/hoists be removed
from the elements until the active season
begins. A frequent inspection must be conducted and documented prior to the first
use of a seasonal hoist.
6.2.2.4 Periodic (Annual) Inspection
Each overhead crane/hoist shall be given a periodic inspection. At a minimum this
inspection shall be conducted every twelve months and include an examination of the
following areas:
• The items in the frequent inspection
• Measurement of the chain or wire rope and the hook.
• Inspection of the brake unit
• Electrical wiring and instructional decals
• Beam bolts and other attachment hardware
• Bent, cracked or corroded members on the bridge or
runways
• Magnetic particle or dye penetrant non-destructive testing
of all hooks
• Shafts, bearing, bushings and couplings
• Annual Load Test
This inspection shall be documented on NC DOT Overhead
Hoist Inspection “Periodic”, (Annual Form) CC-40. (See
Appendix B: Inspection Forms)
6.2.2.5 Load Testing
A qualified person shall conduct all load tests. All load tests shall be conducted over
the entire scope of the crane travel and shall be documented on the NC DOT
Overhead Crane, Load Test Report. (See Appendix B: Inspection Forms, Load Test
Report, Form CC-41.)
There are several different times when load testing is required. The following
describes those circumstances:
• Initial Load Test
This test is required for any existing overhead crane/hoist
that does not have documented proof of previous load
testing as outlined in this Safety Policy and Procedure or for
any new overhead crane/hoist. The initial load test will be
125% of the desired rating.
• Periodic “Annual” Inspection
As part of the periodic or annual inspection, each overhead
crane/hoist shall be load tested at a minimum of 100% but
not to exceed 125% of the rated load capacity.
• After Load-handling component repair or replacement
Anytime an overhead crane/hoist load-handling component
has been repaired or replaced, the overhead crane/hoist shall
be load tested. The load test shall be a minimum of 100%,
but shall not exceed 125% of rated capacity.
6.2.3 General Operation and Use
6.2.3.1 Training of Operators
All employees shall be trained in the proper pre-use inspection
and operation of an overhead crane and hoist. This training
should be completed before an employee begins using an
overhead crane/hoist. It is recommended that re-training occur
every three years or when equipment or job conditions change.
Re-training should also occur if there is an indication or
incident that suggests lack of knowledge or skill.
A qualified person shall conduct or direct this training.
6.2.3.2 Hosting Practices
The operator shall practice the following good operation practices:
• The operator shall be focused on the operation of the
overhead crane/hoist and the load.
• Each operator is responsible for the load while it is under
his or her control. If there is any questions as to the safety
of the lift; then the operator shall stop operations until safety
has been assured.
• No load shall be left unattended when not landed.
• The overhead crane/hoist shall be operated in a smooth
deliberate manner and shock loading shall be avoided.
• The overhead crane/hoist shall not be loaded above the
rated load limit.
• The load shall be directly under the hoist to prevent the load
from swinging when lifted. (Use tag lines as needed)
• The slings shall be inspected visually for damage prior to
use and shall not be overloaded.
• Slings and other lifting devices must be fully and securely
seated in the hook before lifting the load.
• The load shall not be carried or positioned over personnel.
• Employees in the direction of travel should be warned to
move and stay clear of the load at all times.
6.2.3.3 Handling the load
Only personnel trained in the safe operation of an overhead crane or hoist shall
operate this equipment. No load will be moved until:
• All precautions have been taken to ensure that the load does
not exceed the posted rated capacity of the overhead
crane/hoist system.
• It has been determined that the load can be lifted, moved and
lowered in a safe manner.
• All personnel are clear of pinch points.
6.2.3.4 Lockout/Tagout of Overhead Crane/Hoist
Any overhead crane/hoist that is unsafe, in need of repair or in the process of being
repaired shall be:
• Rendered inoperable by disconnecting the power supply and
attaching a lockout device and tag if an electric type of
overhead crane/hoist or chained together with a lock and tag
if a manual chain fall type hoist.
• The control panel shall be tagged with a tag that reads: Do
Not Operate.
Employees should never operate an overhead crane/hoist that has been tagged with a
“Do Not Operate” tag.
6.3. Specific Responsibilities
6.3.1 Managers/Unit Heads
Managers/Unit Heads will be responsible for:
• Ensuring adequate funds are available and budgeted for the purchase of overhead
cranes and hoist as well as replacement components in their areas.
6.3.2 County Maintenance Engineers, Bridge Maintenance Supervisors, Equipment
Sub-shop Supervisors, Ferry Superintendents and Rail Operations Manager will
be responsible for:
County Maintenance Engineers, Bridge Maintenance Supervisors, Equipment Sub-shop
Supervisors, Ferry Superintendents and Rail Operations Manager will be responsible for
• Identifying the employees within their unit that are affected by this safety policy and
procedure
• Coordinating the required training for the affected employees
• Coordinating the Periodic “annual” inspection of overhead cranes/hoists
• Ensuring that pre-use and “Frequent” inspections of overhead cranes/hoist are
conducted.
• Consulting with a qualified person regarding overhead crane installation and
inspection
• Ensuring compliance with this safety policy and procedure.
6.3.3 Qualified person
Qualified person will be responsible for:
• Solving or resolving problems relating to overhead crane systems such as the design,
installation, frequent and periodic inspection and load testing.
6.3.4. Supervisors
Supervisors will be responsible for:
• Communicating appropriate needs to managers/unit heads
• Ensuring employees have been trained to operate overhead cranes
6.3.5 Employees
Employees will:
• Conduct pre-use inspection
• Each operator is responsible for the load while it is under his or her control. If there
is any questions as to the safety of the lift, the operator shall stop operations until
safety has been assured.
• Operate the overhead crane/hoist in a safe manner
6.3.6. Safety Engineers
Safety Engineers will:
• Provide consultative and audit assistance to ensure effective implementation of this
safety policy and procedure
• Assist in developing or securing required training
6.3.7. Safety and Loss Control
Safety and Loss Control will provide:
• Assistance to managers/unit heads, supervisors, or others as necessary on any matter
concerning this safety policy and procedure.
• Assist in developing or securing required training.
• Assist Purchasing and Central Equipment Unit to ensure that all newly purchased
overhead cranes/hoists complies with current safety regulations and this safety policy
and procedure.
6.3.8. Central Equipment Unit and Division Equipment
Central equipment and/or Division Equipment Sub-shops will provide:
• Qualified persons to conduct Periodic or “annual” inspections of overhead
cranes/hoists
Appendix A: Types of Overhead Cranes/Hoist
Old manual chain fall type hoist
Older electrical hoist having
roller or coil chain.
Electric wire rope type hoist
with motorized travel. Most
commonly found in newer
shop
Appendix A: Types of Overhead Cranes/Hoist (cont.)
Electric hoist, coil chain type.
Underhung crane.
Top running crane.
“A” Frame gantry crane.
Appendix A: Types of Overhead Cranes/Hoist (cont.)
Wall mounted crane.
Hoist on a single runway.
Appendix B: Overhead Crane/Hoist Inspection Forms
NCDOT OVERHEAD CRANE
LOAD TEST REPORT
WO # SAP EQ. #
UNIT # DATE
MAX. CAPACITY HOIST S/N
OSHA 1910.179 (k) (2) Test loads shall not be more than 125% of the rated load unless otherwise
recommended by the manufacturer.
This report shall be placed on record and made readily available to all appointed personnel.
Test loads shall be no less than 100 % of rated capacity.
RATED CAPACITY _ LBS.
TEST LOAD APPLIED LBS.
PROBLEMS FOUND
INSPECTOR DATE
This report shall certify that this overhead crane has lifted the test load in a smooth and predictable
manner. All brakes, bridge trucks, and hoist trolleys are working properly at this time. Any problems
resulting from this test have been repaired or defective parts replaced, and this unit is ready for service.
CC-41 9/99
NCDOT OVERHEAD HOIST INSPECTION “ FREQUENT”
WO # “Inspections shall be made monthly” SAP EQ. #
DATE UNIT #
BRIDGE TRUCK S/N
TROLLEY S/N HOIST MAKE
HOIST S/N
ITEM BASELINE REJECT AT MEASUREMENT SAT UNSAT DATE REPLACED
THROAT THROAT
LOAD
HOOK
“Always follow lock out / tag out procedures. Utilize Warning signs and barriers in the work area before beginning inspections”
CHAIN # BASELINE REJECT AT MEASUREMENT SAT UNSAT DATE REPLACED
WIRE ROPE BASELINE REJECT AT MEASUREMENT SAT UNSAT DATE REPLACED
ITEM SAT UNSAT ITEM SAT UNSAT
OPERATING CONTROLS ELECTRICAL CORD N/A
& REEL
TROLLY & BRIDGE TRAVEL PENDANT CABLE N/A
LUBE CHAIN OIL LEAKS AT HOIST N/A
TRUCK & TROLLEY WHEELS CHAIN LIMIT SWITCH N/A
FOR DAMAGE OPERATION
TRUCK & TROLLEY SIDE PLATE HOIST CHAIN SMOOTH
ADJUSTMENT OPERATION
TRUCK & TROLLEY N/A TOP HOOK VISUAL N/A
WHEEL LUBE
BEAMS FOR DAMAGE HOOK SAFETY LATCHES
FOR FAULTY ITEMS USE REMARK SECTION
Inspector Date
All deficiencies shall be carefully examined and a determination made as to whether or not they constitute a safety hazard. Any hoist found to be unsafe
shall be taken out of service until it can be repaired or defective parts are replaced.
CC-39 7/04
NCDOT OVERHEAD HOIST INSPECTION
“PERIODIC”
“Inspections shall be made Annually.”
DATE UNIT#
BRIDGE TRUCK S/N
TROLLEY S/N HOIST MAKE
HOIST S/N
“Periodic inspections shall be performed in intervals of no less than one
year”
You are required to read and consult the manual for hoist/crane that is to be
inspected. This checklist is in no way intended to replace it.
ITEM Sample Form ITEM
SAT UNSAT SAT UNSAT
NCDOT FREQUENT INSPECTION BENT, CRACKED, OR CORRODED
MEMBERS ON BRIDGE OR RUN
For onlineWAYform,
INSPECT HOIST BRAKE otUNIT
see:http://www.doh.dot.state.nc.us/forms/files/CC-
MAG PARTICLE OR DYE PEN
( refer to hoist manual ) TEST OF BOTH HOOKS
DAMAGED OR WORN LOAD
40.doc ALL PINS, SHAFTS, BEARINGS,
SHEAVE BUSHINGS, AND COUPLINGS
ALL WARNING AND LUBE HOIST AS PER MANUAL
INSTRUCTIONAL DECALS
ALL ELECTRICAL N/A PERFORM OPERATIONAL AND
CONNECTIONS AND LOAD TEST
WIRE CONDITION
ALL BEAM BOLTS OR OTHER
ATTACHING HARDWARE
FOR FAULTY ITEMS USE REMARK SECTION
SHOP SUPERVISOR
DATE
INSPECTOR DATE
All deficiencies shall be carefully examined and a determination made as to whether
or not they constitute a safety hazard. Any hoist found to be unsafe shall
be taken out of service until it can be repaired or defective parts are replaced.
CC-40, 12/99
