Maintenance & Reliability · SOP

Overhead Bridge Crane Pre-Shift Sling and Hoist Inspection

A comprehensive, highly-technical standard operating procedure for performing a pre-shift inspection on overhead bridge crane hoists, slings, and rigging components. Fully aligned with CSA B167 and ASME B30 standards.

Estimated Time

25 min

Difficulty

Intermediate

Regulation

CSA B167 / ASME B30

Version

1.2

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Purpose

Ensure the structural integrity and operational safety of the overhead bridge crane, hoist, slings, and rigging hardware prior to first use of the shift. The objective is to systematically identify any damage, wear, deformation, or malfunction that could directly lead to a dropped load, catastrophic rigging failure, equipment damage, or severe personnel injury. This procedure establishes a strict, repeatable baseline for defect recognition and mandatory lockout/tagout protocols.

Scope

This procedure applies strictly to all operators, millwrights, and maintenance personnel responsible for performing a pre-shift inspection on overhead bridge cranes (rated capacity 1 ton to 100 tons) within the facility. It encompasses a thorough examination of the hoist mechanism, wire rope, rigging slings (synthetic, wire, chain), hooks, load block, trolley assembly, bridge structure, runway rails, and all electrical/mechanical limit devices. This is a pre-operational inspection; it does not cover detailed preventative maintenance or load testing.

Safety Precautions

LOTOLockout/Tagout: Complete isolation of the main disconnect switch for the crane is mandatory before accessing any electrical panels, brakes, or drivetrain components. Verify zero energy state with a qualified electrician if required.
PPEHard hat, safety glasses with side shields, high-visibility vest, steel-toed boots, and heavy-duty rigging gloves. Full-body harness with shock-absorbing lanyard is required when working from elevated platforms or on the crane bridge.
BARRBarricade: Establish a clearly marked caution zone or barricade on the floor directly beneath the crane inspection area. Absolutely no personnel shall pass under a suspended load or a moving crane during the inspection cycle.
TAGTag Out: Immediately tag the crane "OUT OF SERVICE — DO NOT OPERATE" at both the floor level and the pendant if any critical defect is found. Notify the shift supervisor and submit a formal work order before the crane is used.

Required Tools & Materials

Inspection checklist / clipboard (OEM or facility-standard)
High-lumen rechargeable flashlight (minimum 1000 lumens)
Calibrated tape measure (metric/imperial) for sling length and hook throat stretch
Wire rope caliper (pin-type or digital, for diameter reduction check)
Torque wrench (for verifying bolted connections on rail splices and end stops)
Digital camera or tablet for photo documentation of defects
Lockout/tagout kit (personal padlocks, group hasps, "DANGER" tags)
Cleaning rags and industrial solvent (for removing grease/debris from inspection points)
OEM-specified lubricant for hoist chain or wire rope (if required post-inspection)

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Procedure: Step-by-Step

1 Pre-Inspection Setup: Don full PPE and establish a hard barricade beneath the crane bay. Review the previous shift's inspection log. If the crane carries a red "Out of Service" tag, do not proceed — contact the maintenance supervisor immediately.

2 Bridge & Runway Visual: Walk the length of the runway rails. Inspect for shifted or cracked rail joints, loose or missing bolts in the rail clips, and any debris on the rail surface. Verify the bridge end stops are securely bolted and free of impact damage.

3 Hoist Trolley & Drivetrain: Manually push or inch the trolley along the bridge. Listen for grinding or knocking. Inspect trolley wheels for flat spots, flaking, or excessive wear. Check gearbox breather and seals for active oil leaks.

4 Wire Rope Hoist Inspection (Critical): Slowly jog the hoist through its full vertical range. Run a clean rag along the rope to feel for broken wires, kinks, or corrosion. Count broken wires: reject if more than 12 broken wires in one lay length or 6 in one strand. Measure rope diameter with a caliper — reject if worn beyond 5% of nominal diameter or if bird-caging is visible.

5 Sling Inspection (Synthetic / Wire / Chain): Unroll and lay each sling flat on a clean surface. Inspect synthetic web for cuts, abrasion, acid burns, or UV degradation (fading or chalking). For chain slings, measure link diameter with calipers — reject if wear exceeds 10% of original size. Reject any sling with a missing, illegible, or non-compliant ID tag.

6 Hook & Throat Inspection: Using a tape measure or dedicated hook gauge, measure the throat opening distance. Reject the hook if the opening has stretched more than 15% of its original dimension. Check for twisting of the hook shank (>10 degrees is a reject). Verify the safety latch closes freely and the spring returns with full tension.

7 Brake & Clutch Function Test: With the hoist empty, jog the "UP" button and immediately release. The load brake must stop and hold the block instantly with zero drift. Repeat for the "DOWN" direction. If equipped, test the mechanical load brake by holding a test weight (110% of rated capacity) for 60 seconds.

8 Limit Switch Verification: Slowly raise the empty hook block to trigger the upper limit switch. The crane motor must cut off before the block or load bar contacts the drum or frame. Manually test the lower limit switch and all trolley/bridge travel limit switches.

9 Control & Pendant Inspection: Inspect the full length of the pendant cord for cuts, crushed areas, or exposed wiring. Actuate each pushbutton and verify it snaps back freely upon release. Press and twist the E-Stop button; it must latch and cut all hoist/bridge power immediately.

10 Documentation & Sign-Off: Record all findings, including slack adjustments and measurements, on the inspection log. If the crane passes every checkpoint, sign off and attach a green "Inspected" tag to the pendant. If any critical defect is found, complete a red "Out of Service" tag, secure the lockout, and submit a work order immediately.

Overhead Bridge Crane Pre-Shift Sling and Hoist Inspection

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