Inspection & Maintenance

Core · Domain: Inspection & Maintenance · ~25 min · OSHA 1926 Subpart CC + ASME B30.5-2025 (Authored & cited — pending SME review.)

1. The inspection system — a layered net

Five inspection types form a layered net, each catching what the faster, shallower layers miss:

• Each-shift — frequent, shallow, visual. Catches fast-developing problems before the first pick.
• Monthly — same scope as each-shift but documented and signed. Creates a paper trail.
• Annual — infrequent, deep, may require disassembly. Catches slow killers: internal corrosion, cracked welds, worn gears.
• Post-assembly — event-triggered after build-up. Catches assembly errors before first use.
• Modified/repaired/adjusted — event-triggered when load-sustaining parts are altered.

The defect rule is binary: when an inspection turns up a deficiency, a qualified person determines whether it is a hazard. A hazardous condition must be corrected before the crane goes back to work (ASME B30.5-2025 §5-2.3.3(a)). There is no "finish this one lift first."

Cited: OSHA 29 CFR 1926.1412; ASME B30.5-2025 Chapter 5-2.

2. Key terms

• Designated person — selected/assigned by the employer as competent to perform a specific task. Performs routine (shift and monthly) inspections (§5-2.1(a)).
• Qualified person — sufficient degree, certificate, or extensive knowledge/training/experience to solve problems in the subject. Judges whether a deficiency is a hazard; performs post-assembly and annual inspections (§5-2.1(a); §5-2.1.2; §5-2.1.5).
• Operational aid — device that assists the operator: anti-two-block, rated-capacity limiter/indicator, boom angle/length indicator (OSHA 1926.1416; ASME §5-2.1.8).
• Safety device — device that protects regardless of operator action: boom stops, locks, level indicator, horn (OSHA 1926.1415).
• Removal criteria — specific thresholds at which wire rope or a hook must be taken out of service (29 CFR 1926.1413; ASME §5-2.4 via ASME B30.30).

Test trap: "operational aid" vs. "safety device." The anti-two-block is an operational aid (assists the operator) — not a safety device. The distinction matters on the exam.

3. Each-shift inspection — visual, every shift, designated person

Before initial use each shift: a visual inspection for apparent deficiencies (§5-2.1.3; OSHA 1926.1412). Disassembly and lowering the boom are not required unless something prompts a deeper look.

Check at minimum:

• Control mechanisms for maladjustment and excessive wear/contamination (§5-2.1.3(a),(b)).
• Structural members for damage or deformation observable from the ground (§5-2.1.3(c)).
• Operational aids for malfunction; check per manufacturer prior to initial use per shift (§5-2.1.3(d); §5-2.1.8(a)).
• Air/hydraulic/pressurized lines for deterioration or leakage, especially flexing lines (§5-2.1.3(e)).
• Hooks and latches for deformation, chemical damage, cracks, and wear — per ASME B30.10 (§5-2.1.3(f)).
• Rope reeving for compliance with manufacturer / qualified-person recommendations (§5-2.1.3(g)).
• Electrical apparatus, hydraulic oil level, tires, level position (before each shift and after each move), cab windows for view-obstructing cracks (§5-2.1.3(h)–(l)).

4. Monthly inspection — documented, retained 12 months

Each month in service: repeat the §5-2.1.3 inspection, then document it (§5-2.1.4). The crane shall not be used until a monthly inspection shows no immediate corrective action is required.

Record: items checked and results; inspector's name and signature; date. Retain the record at least 12 months, readily available at the jobsite (§5-2.1.4(b); §5-2.1.7(a)).

5. Annual (comprehensive) inspection — qualified person, at least every 12 months

At least every 12 months a qualified person performs the §5-2.1.3 inspection plus a deep examination — disassembly and lowering the boom/jib may be necessary (§5-2.1.5).

Scope includes:

• Structure — members for deformation/cracks/significant corrosion; fasteners for looseness; welds for cracks (§5-2.1.5(a)).
• Sheaves and drums for cracks or significant wear (§5-2.1.5(b)).
• Pins, bearings, shafts, gears, rollers, locking devices; brakes/clutches, linings, pawls, ratchets (§5-2.1.5(c),(d)).
• Operational aids for proper functionality and significant inaccuracy (§5-2.1.5(e); §5-2.1.8(b)).
• Power plant, hydraulic/pneumatic hoses, pumps, motors, valves, cylinders, filters, outrigger pads (§5-2.1.5(f),(k)–(q)).
• Hooks/latches, electrical wiring/insulation, warning labels/decals, safety hardware (§5-2.1.5(h),(r)–(w)).
• Function testing to confirm the crane works properly as configured (§5-2.1.5(x)).

Records: items inspected, results, inspector name and signature, date. Retained 12 months, available at the jobsite (§5-2.1.7(b)).

6. Post-assembly inspection — qualified person, before first use after build

Upon completing assembly and before use, a qualified person inspects to confirm configuration per manufacturer instructions (§5-2.1.2; OSHA 1926.1412). Catches reeving errors, missing pins, mis-rigged counterweight — defects that only exist after a build.

7. Modified / repaired / adjusted — load test before return to service

Cranes whose load-sustaining parts were altered, replaced, or repaired should be load tested by or under the direction of a qualified person before initial use (§5-2.2.2(b)).

• Rope replacement exception: no load test required, but a functional test under a normal operating load should be done before returning to service (§5-2.2.2(b)(1)).
• A designated person furnishes written reports confirming the adequacy of the repair (§5-2.2.2(b)(2)).

Cranes not in regular use:

• Idle 1–6 months → §5-2.1.3 + rope inspection before returning to service.
• Idle over 6 months → full §5-2.1.5 + rope inspection.
• Standby cranes → at least semiannual §5-2.1.3 + rope inspection (§5-2.1.6).

8. Wire rope — inspection and removal criteria

Wire rope has its own dedicated inspection because it degrades continuously and fails progressively. OSHA addresses it separately: inspection at 29 CFR 1926.1413 and selection/installation criteria at 29 CFR 1926.1414; ASME B30.5-2025 §5-2.4 routes rope inspection to ASME B30.30.

A rope must be removed from service when it shows:

• Twelve randomly distributed broken wires in one rope lay, or four broken wires in one strand in one rope lay.
• Wear of 1/3 the original diameter of outside individual wires.
• Kinking, crushing, bird-caging, or any distortion altering the rope's structure.
• Evidence of heat damage.
• Reductions from nominal diameter greater than the standard allows.
• Hook-end attachments with damage as defined by B30.10.

Test trap: "12 randomly distributed broken wires" is in one rope lay, not total. And the threshold differs for running rope vs. standing rope (B30.30 governs the specifics).

9. Worked scenario — a deficiency found mid-shift

60-ton hydraulic truck crane, full day of steel sets. You run the each-shift inspection.

1. Walk-around. Controls free, structure clean from the ground; anti-two-block and RCL both cycle (§5-2.1.3(d); §5-2.1.8(a)).
2. Find defects. Hydraulic hose to the hoist motor shows blistering and an oil film at the fitting (§5-2.1.3(e)). Hoist rope near the dead-end has broken wires plus a short crushed section.
3. Stop and classify. Do not lift. A deficiency is found → a qualified person determines whether it's a hazard (§5-2.1(a)).
4. Hose — abnormal outer-cover deformation is a defect; condemned and replaced.
5. Rope — crushing + broken wires meet removal criteria (1926.1413; ASME §5-2.4 via B30.30). Removed. Rope replacement is excluded from full load testing, so after swap run a functional test under normal load before returning to service (§5-2.2.2(b)(1)).
6. Document, then resume. Log the deficiency and correction (§5-2.1.7(c)); work resumes only after the hazard is corrected (§5-2.3.3(a)).

The exam judgment isn't "spot the blister" — it's stop → qualified person classifies → correct → document → resume.

Common traps

• Thinking the operator performs the annual inspection — it's a qualified person.
• Thinking the monthly inspection adds new scope — it is the same as shift-inspection scope, just documented.
• Missing the rope replacement exception — no load test, but functional test required.
• Confusing operational aid (anti-two-block) with safety device (boom stop).
• Forgetting standby cranes still require semiannual inspections.

Now test yourself

→ Practice: Inspection & Maintenance — inspection type, frequency, who performs it, removal criteria, and the binary defect rule.