A crane may pass thousands of lifts without incident. But a missed crane inspection can turn a minor fault into a major failure. Structured, documented inspections are not optional; they’re your first line of defence.

Let’s unpack daily and monthly checks, how often to book detailed examinations, what to record, and how to stay audit-ready with clear documentation.

Crane Inspection Frequency

Follow a clear inspection cadence: operators carry out daily pre-use checks before each shift; a competent person completes monthly inspections using a documented checklist; cranes in regular service or tougher environments receive six-monthly visual examinations; and an annual inspection includes a full functional test with a signed report. Always schedule an extra inspection after any major repair, modification, or incident.

Regulatory Requirements

In South Africa, the Driven Machinery Regulations (DMR 18) and SANS 10375 set out minimum inspection intervals and require that all cranes be examined by a competent person at prescribed intervals. In the UK, LOLER 1998 under the Health and Safety Executive (HSE) framework mandates similar inspection schedules and documentation standards.

Following these regulations not only keeps operations compliant but also helps standardise inspection routines across multi-site operations.

Overhead Crane Structural Inspections

A comprehensive inspection of an overhead crane includes detailed evaluation of the main bridge structure, end carriages and runway system. Inspectors assess the condition of runway rails, end stops, buffers, and conductor systems to ensure the crane travels smoothly and safely along its full span. Alignment of the rails and wheels is verified, with any skew or uneven wear recorded for trend analysis between inspection intervals.

The bridge structure and end carriages are reviewed for signs of stress, deformation, or loose fasteners that could affect stability or travel accuracy. Wheel condition, bearing function, and braking performance are checked to confirm consistent operation and controlled stopping under load.

In facilities using gantry-mounted systems, the same inspection principles apply – with additional attention to ground tracks and wheel alignment on both sides of the gantry. Inspectors also review power transmission systems such as festoons, cable reels, or conductor bars to ensure safe movement without wear, obstruction or cable strain.

These combined assessments verify that the crane’s structure and travel path remain true, stable, and compliant with the required performance and safety standards.

Crane Inspection Procedure

1. Document Review

Each inspection begins with a review of asset documentation, including the crane’s identification record, previous inspection sheets, defect close-out reports and OEM manuals. This establishes a reference for known issues and helps identify recurring trends.

2. Visual Examination

Inspectors conduct a full walk-around assessment of the crane structure, welds, fasteners, runway beams, stop blocks and safety signage. The focus is on identifying visible damage, deformation or signs of fatigue.

3. Mechanical Components

The mechanical systems are examined to confirm reliable function and condition. This includes the hoist, brakes, couplings, hooks, latches, sheaves, rope reeving, chains, end carriages and buffers. Gearboxes and couplings are checked for leaks or unusual wear patterns.

4. Ropes and Chains

Wire ropes and load chains are measured and visually assessed for broken wires, corrosion, diameter reduction, pitch elongation and groove wear on drums and sheaves. These indicators provide early warning of fatigue or overload.

5. Electrical and Control Systems

The crane’s electrical circuits and control interfaces are function-tested. This includes pendant or radio systems, emergency stops, limit switches, overload protection, and earthing continuity to ensure all safety devices operate correctly.

6. Operational Testing

Functional testing is carried out under both no-load and rated-load conditions. Movements in lifting, lowering, cross-travel, and long-travel are observed to evaluate stopping distances, smoothness, speed control, and any unusual noise or vibration.

7. Reporting and Close-Out

Findings are documented in a formal inspection report, with defects graded by severity and supported by photographic evidence where appropriate. Corrective actions and target completion dates are recorded to ensure traceability and compliance.

Daily crane Inspections

Daily crane inspections confirm that essential safety and operational systems are functioning correctly before use. Inspectors verify the power supply, emergency stop, and warning devices; ensure control pendants or remotes respond accurately; and confirm that the hook, latch, and swivel move freely. The wire rope or chain must be free from kinks, birdcaging, or wear, and limit switches, hoist, trolley, and bridge motions should operate smoothly without abnormal noise. The area below the hook and along the runway is kept clear to maintain safe crane travel and lifting operations.

Monthly crane Inspections

Monthly inspections provide a deeper review of the crane’s structure, mechanics, and safety devices. Inspectors assess the condition of main members, welds, fasteners, and runway beams; measure wheel alignment and bearing performance; and verify hoist and brake function. Drums, sheaves, and cables are checked for wear or misalignment, while electrical systems, limiters, and anti-collision devices are tested for reliability. Markings and safe working load labels are confirmed as visible and legible, ensuring the crane remains compliant, traceable, and safe for continued operation.

Crane Lifting Inspection and Major Inspection

A lifting inspection verifies that the crane lifts along a safe path with the correct capacity and functioning safety devices during a controlled load test. A major inspection is a deeper life-extension review that may include NDT on critical welds, gearbox strip-downs, control upgrades, and recommendations for refurbishment. Timing depends on duty class, age, and operating environment.

Inspection Documentation and Traceability

Comprehensive record keeping is a key part of regulatory compliance and asset management. Each inspection generates a documented record that includes the items assessed, outcomes, photographic evidence where relevant, and a graded summary of any defects or recommendations. Standardised reporting formats allow supervisors, auditors, and service teams to track trends and verify that inspection actions are completed on schedule.

Crane Inspection Expertise at RGM Cranes

RGM Cranes applies these inspection principles across its full range of overhead lifting solutions. The company’s inspection programmes are structured around national standards such as SANS 10375 and LOLER 1998, combining detailed technical assessment with clear, traceable reporting. Each inspection is carried out by qualified crane specialists who understand the operational demands of industrial environments, helping clients maintain compliance, extend equipment life, and prevent costly downtime.

Frequently asked questions

How often must a crane be inspected?

Daily pre-use checks; monthly inspections; six monthly visual exams for regular or harsh service; annual thorough exam with functional test; and after any installation, repair, modification or incident.

What is the checklist for crane inspection?

Asset ID and history; structure; wheels and rails; hoist, brakes and drives; hook, ropes or chains and sheaves; electrics and controls; safety devices and markings; operational tests; documentation and sign off.