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Overhead Crane and Hoist Periodic Inspection: Complete Guide
Cranes and hoists carry load over people: rope discard criteria, hook throat, brake holding and limiter function are the core of the annual control. This guide walks through the step-by-step audit and the typical non-conformities.
Overhead crane and hoist periodic inspection audits the whole lifting chain — rope, hook, block, brake, drum, rope winding and rated-capacity limiter — with measurement and function trials; it is a yearly duty. The people under the lifted load make these machines the highest-consequence risk source of the site: for a parted rope or a brake that will not hold there is no second chance. Under the regulation the control runs yearly, and a load proof is repeated in doubtful cases. Main reference: lifting and handling machine periodic inspection.
The Chain: From Rope to Limiter
- Rope: wire breaks per pitch, wear-corrosion, diameter loss and birdcaging; evaluated with ISO 4309 discard criteria — rope change logged.
- Hook and latch: throat opening measurement (permitted limit), latch spring pressure, neck wear; magnetic-particle examination in doubt.
- Brake and drum: holding in lift position (slip distance), pad wear, drum flange integrity.
- Limiters: upper limit switch, load moment/weight limiter (LMI) setting verification; final limits and rail buffers.
- Structural: bridge and girder weld zones, wheel-cam wear, rail alignment, festoon supply line.
When the Load Proof?
As a routine the proof follows repair-replacement, suspect findings and manufacturer or regulatory duty: static typically above nominal capacity (a 1.25 practical approach), dynamic at nominal load; brake holding and limiter cut verified under load. The working area is cleared before the trial and no person stays under the load — this is a safety procedure, not formality.
Follow-up: Report and Usage Discipline
The report carries every finding with measurement and limit: on critical findings (rope beyond limit, slipping brake, disabled LMI) the crane is tagged and returns only after repair-verification. The daily operator pre-use check (rope-hook-brake-sound-alarm) must be logged, and the separate periodic examination of slings and accessories (sling inspection) must not be forgotten — the weakest link of the chain is usually the accessory. For hoist-based stations, chain-tension and cover protection steps are on our chain hoist service page.
Author: KYF Test Engineering Team • Last updated: September 2026