Overhead Crane Inspector Recertification Online Attachment

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OSHA 1910.179 Overhead and Gantry Cranes

OSHA 1926 Subpart CC Cranes and Derricks

ASME B30.2 (2011) Overhead and Gantry Cranes

ASME B30.11 (2010) Monorails and Underhung Cranes

ASME B30.16 (2007) Overhead Hoists (Underhung)

 OSHA 1910.179
Overhead and Gantry Cranes
1910.179(a) Definitions applicable to this by the employer or the employers representative.
section (16) ANSI means the American National Standards
(1) A crane is a machine for lifting and lowering a load
and moving it horizontally, with the hoisting mechanism an
integral part of the machine. Cranes whether fixed or mobile
are driven manually or by power.
(2) An automatic crane is a crane which when activated
operates through a preset cycle or cycles.
(3) A cab-operated crane is a crane controlled by an
operator in a cab located on the bridge or trolley.
(4) Cantilever gantry crane means a gantry or semi-
gantry crane in which the bridge girders or trusses extend
transversely beyond the crane runway on one or both sides.
(5) Floor-operated crane means a crane which is pendant
or nonconductive rope controlled by an operator on the floor
or an independent platform.
(6) Gantry crane means a crane similar to an overhead
crane except that the bridge for carrying the trolley or trolleys
is rigidly supported on two or more legs running on fixed rails
or other runway.
(7) Hot metal handling crane means an overhead crane
used for transporting or pouring molten material.
(8) Overhead crane means a crane with a movable bridge
carrying a movable or fixed hoisting mechanism and traveling
on an overhead fixed runway structure.
(9) Power-operated crane means a crane whose mecha-
nism is driven by electric, air, hydraulic, or internal combus-
tion means.
(10) A pulpit-operated crane is a crane operated from
a fixed operator station not attached to the crane.
(11) A remote-operated crane is a crane controlled by
an operator not in a pulpit or in the cab attached to the crane,
by any method other than pendant or rope control.
(12) A semigantry crane is a gantry crane with one end
of the bridge rigidly supported on one or more legs that run
on a fixed rail or runway, the other end of the bridge being
supported by a truck running on an elevated rail or runway.
(13) Storage bridge crane means a gantry type crane
of long span usually used for bulk storage of material; the
bridge girders or trusses are rigidly or nonrigidly supported
on one or more legs. It may have one or more fixed or hinged
cantilever ends.
(14) Wall crane means a crane having a jib with or with-
out trolley and supported from a side wall or line of columns
of a building. It is a traveling type and operates on a runway
attached to the side wall or columns.
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(15) Appointed means assigned specific responsibilities
Institute.
(17) An auxiliary hoist is a supplemental hoisting unit
of lighter capacity and usually higher speed than provided for
the main hoist.
(18) A brake is a device used for retarding or stopping
motion by friction or power means.
(19) A drag brake is a brake which provides retarding
force without external control.
(20) A holding brake is a brake that automatically pre-
vents motion when power is off.
(21) Bridge means that part of a crane consisting of gird-
ers, trucks, end ties, footwalks, and drive mechanism which
carries the trolley or trolleys.
(22) Bridge travel means the crane movement in a direc-
tion parallel to the crane runway.
(23) A bumper [buffer] is an energy absorbing device
for reducing impact when a moving crane or trolley reaches
the end of its permitted travel; or when two moving cranes
or trolleys come in contact.
(24) The cab is the operators compartment on a crane.
(25) Clearance means the distance from any part of the
crane to a point of the nearest obstruction.
(26) Collectors current are contacting devices for col-
lecting current from runway or bridge conductors.
(27) Conductors, bridge are the electrical conductors
located along the bridge structure of a crane to provide power
to the trolley.
(28) Conductors, runway [main] are the electrical con-
ductors located along a crane runway to provide power to the
crane.
(29) The control braking means is a method of control-
ling crane motor speed when in an overhauling condition.
(30) Countertorque means a method of control by which
the power to the motor is reversed to develop torque in the
opposite direction.
(31) Dynamic means a method of controlling crane
motor speeds when in the overhauling condition to provide a
retarding force.
(32) Regenerative means a form of dynamic braking
in which the electrical energy generated is fed back into the
power system.
(33) Mechanical means a method of control by friction.
(34) Controller, spring return means a controller which
when released will return automatically to a neutral position.
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1910.179(a) Definitions (contd)
(35) Designated means selected or assigned by the em-
ployer or the employers representative as being qualified to
perform specific duties.
(36) A drift point means a point on a travel motion
controller which releases the brake while the motor is not
energized. This allows for coasting before the brake is set.
(37) The drum is the cylindrical member around which
the ropes are wound for raising or lowering the load.
(38) An equalizer is a device which compensates for
unequal length or stretch of a rope.
(39) Exposed means capable of being contacted inadver-
tently. Applied to hazardous objects not adequately guarded
or isolated.
(40) Fail-safe means a provision designed to automati-
cally stop or safely control any motion in which a malfunction
occurs.
(41) Footwalk means the walkway with handrail, attached
to the bridge or trolley for access purposes.
(42) A hoist is an apparatus which may be a part of a
crane, exerting a force for lifting or lowering.
(43) Hoist chain means the load bearing chain in a hoist.
NOTE: Chain properties do not conform to those shown in
ANSI B30.9-1971, Safety Code for Slings.
(44) Hoist motion means that motion of a crane which
raises and lowers a load.
(45) Load means the total superimposed weight on the
load block or hook.
(46) The load block is the assembly of hook or shackle,
swivel, bearing, sheaves, pins, and frame suspended by the
hoisting rope.
(47) Magnet means an electromagnetic device carried
on a crane hook to pick up loads magnetically.
(48) Main hoist means the hoist mechanism provided
for lifting the maximum rated load.
(49) A man trolley is a trolley having an operators cab
attached thereto.
(50) Rated load means the maximum load for which a
crane or individual hoist is designed and built by the manu-
facturer and shown on the equipment nameplate(s).
(51) Rope refers to wire rope, unless otherwise specified.
(52) Running sheave means a sheave which rotates as
the load block is raised or lowered.
(53) Runway means an assembly of rails, beams, girders,
brackets, and framework on which the crane or trolley travels.
(54) Side pull means that portion of the hoist pull acting
horizontally when the hoist lines are not operated vertically.
(55) Span means the horizontal distance center to center
of runway rails.
(56) Standby crane means a crane which is not in regular
service but which is used occasionally or intermittently as
required.
(57) A stop is a device to limit travel of a trolley or crane
bridge. This device normally is attached to a fixed structure and
normally does not have energy absorbing ability.
(58) A switch is a device for making, breaking, or for
changing the connections in an electric circuit.
(59) An emergency stop switch is a manually or auto-
matically operated electric switch to cut off electric power
independently of the regular operating controls.
(60) A limit switch is a switch which is operated by some
part or motion of a power-driven machine or equipment to alter
the electric circuit associated with the machine or equipment.
(61) A main switch is a switch controlling the entire
power supply to the crane.
(62) A master switch is a switch which dominates the
operation of contactors, relays, or other remotely operated
devices.
(63) The trolley is the unit which travels on the bridge
rails and carries the hoisting mechanism.
(64) Trolley travel means the trolley movement at right
angles to the crane runway.
(65) Truck means the unit consisting of a frame, wheels,
bearings, and axles which supports the bridge girders or trolleys.
1910.179(b) General requirements
(1) Application. This section applies to overhead and gantry
cranes, including semigantry, cantilever gantry, wall cranes,
storage bridge cranes, and others having the same fundamental
characteristics. These cranes are grouped because they all have
trolleys and similar travel characteristics.
(2) New and existing equipment. All new overhead and
gantry cranes constructed and installed on or after August 31,
1971, shall meet the design specifications of the American
National Standard Safety Code for Overhead and Gantry
Cranes, ANSI B30.2.0-1967, which is incorporated by refer-
ence as specified in Sec. 1910.6.
(3) Modifications. Cranes may be modified and rerated
provided such modifications and the supporting structure
are checked thoroughly for the new rated load by a qualified
engineer or the equipment manufacturer. The crane shall be
tested in accordance with paragraph (k) (2) of this section.
New rated load shall be displayed in accordance with sub-
paragraph (5) of this paragraph.
(4) Wind indicators and rail clamps. Outdoor storage
bridges shall be provided with automatic rail clamps. A wind-
indicating device shall be provided which will give a visible
or audible alarm to the bridge operator at a predetermined
wind velocity. If the clamps act on the rail heads, any beads or
weld flash on the rail heads shall be ground off.
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1910.179(b) General Requirements (contd)
(5) Rated load marking. The rated load of the crane shall
be plainly marked on each side of the crane, and if the crane
has more than one hoisting unit, each hoist shall have its rated
load marked on it or its load block and this marking shall be
clearly legible from the ground or floor.
(6) Clearance from obstruction.
(i) Minimum clearance of 3 inches overhead and 2 inches
laterally shall be provided and maintained between crane
and obstructions in conformity with Crane Manufacturers
Association of America, Inc, Specification No. 61, which is
incorporated by reference as specified in Sec. 1910.6, (for-
merly Electric Overhead Crane Institute, Inc).
(ii) Where passageways or walkways are provided ob-
structions shall not be placed so that safety of personnel will
be jeopardized by movements of the crane.
(7) Clearance between parallel cranes. If the runways of
two cranes are parallel, and there are no intervening walls
or structure, there shall be adequate clearance provided and
maintained between the two bridges.
(8) Designated personnel. Only designated personnel shall
be permitted to operate a crane covered by this section.
1910.179(c) Cabs
(1) Cab location.
(i) The general arrangement of the cab and the location of
control and protective equipment shall be such that all operat-
ing handles are within convenient reach of the operator when
facing the area to be served by the load hook, or while facing
the direction of travel of the cab. The arrangement shall allow
the operator a full view of the load hook in all positions.
(ii) The cab shall be located to afford a minimum of 3
inches clearance from all fixed structures within its area of
possible movement.
(2) Access to crane. Access to the cab and/or bridge walk-
way shall be by a conveniently placed fixed ladder, stairs, or
platform requiring no step over any gap exceeding 12 inches.
Fixed ladders shall be in conformance with the American
National Standard Safety Code for Fixed Ladders, ANSI
A14.3-1956, which is incorporated by reference as specified
in Sec. 1910.6.
(3) Fire extinguisher. Carbon tetrachloride extinguishers
shall not be used.
(4) Lighting. Light in the cab shall be sufficient to enable
the operator to see clearly enough to perform his work.
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1910.179(d) Footwalks and ladders
(1) Location of footwalks.
(i) If sufficient headroom is available on cab-operated
cranes, a footwalk shall be provided on the drive side along
the entire length of the bridge of all cranes having the trolley
running on the top of the girders.
(ii) Where footwalks are located in no case shall less than
48 inches of headroom be provided.
(2) Construction of footwalks.
(i) Footwalks shall be of rigid construction and designed to
sustain a distributed load of at least 50 pounds per square foot.
(ii) Footwalks shall have a walking surface of antislip
type. NOTE: Wood will meet this requirement.
(iii) [Reserved]
(iv) The inner edge shall extend at least to the line of the
outside edge of the lower cover plate or flange of the girder.
(3) Toeboards and handrails for footwalks. Toeboards and
handrails shall be in compliance with section 1910.23 of this
part.
(4) Ladders and stairways.
(i) Gantry cranes shall be provided with ladders or
stairways extending from the ground to the footwalk or cab
platform.
(ii) Stairways shall be equipped with rigid and substantial
metal handrails. Walking surfaces shall be of an antislip type.
(iii) Ladders shall be permanently and securely fastened
in place and shall be constructed in compliance with 1910.27.
1910.179(e) Stops, bumpers, rail sweeps,
and guards
(1) Trolley stops.
(i) Stops shall be provided at the limits of travel of the
trolley.
(ii) Stops shall be fastened to resist forces applied when
contacted.
(iii) A stop engaging the tread of the wheel shall be of a
height at least equal to the radius of the wheel.
(2) Bridge bumpers.
(i) A crane shall be provided with bumpers or other au-
tomatic means providing equivalent effect, unless the crane
travels at a slow rate of speed and has a faster deceleration rate
due to the use of sleeve bearings, or is not operated near the
ends of bridge and trolley travel, or is restricted to a limited
distance by the nature of the crane operation and there is no
hazard of striking any object in this limited distance, or is
used in similar operating conditions. The bumpers shall be
capable of stopping the crane (not including the lifted load) at
an average rate of deceleration not to exceed 3 ft/s/s when trav-
eling in either direction at 20 percent of the rated load speed.
1910.179(e) Stops, bumpers, rail sweeps,
and guards (contd)
{a} The bumpers shall have sufficient energy absorbing
capacity to stop the crane when traveling at a speed of at least
40 percent of rated load speed.
{b} The bumper shall be so mounted that there is no
direct shear on bolts.
(ii) Bumpers shall be so designed and installed as to
minimize parts falling from the crane in case of breakage.
(3) Trolley bumpers.
(i) A trolley shall be provided with bumpers or other auto-
matic means of equivalent effect, unless the trolley travels at
a slow rate of speed, or is not operated near the ends of bridge
and trolley travel, or is restricted to a limited distance of the
runway and there is no hazard of striking any object in this
limited distance, or is used in similar operating conditions.
The bumpers shall be capable of stopping the trolley (not
including the lifted load) at an average rate of deceleration
not to exceed 4.7 ft/s/s when traveling in either direction at
one-third of the rated load speed.
(ii) When more than one trolley is operated on the same
bridge, each shall be equipped with bumpers or equivalent
on their adjacent ends.
(iii) Bumpers or equivalent shall be designed and installed
to minimize parts falling from the trolley in case of age.
(4) Rail sweeps. Bridge trucks shall be equipped with
sweeps which extend below the top of the rail and project in
front of the truck wheels.
(5) Guards for hoisting ropes.
(i) If hoisting ropes run near enough to other parts to
make fouling or chafing possible, guards shall be installed to
prevent this condition.
(ii) A guard shall be provided to prevent contact between
bridge conductors and hoisting ropes if they could come into
contact.
(6) Guards for moving parts.
(i) Exposed moving parts such as gears, set screws,
projecting keys, chains, chain sprockets, and reciprocating
components which might constitute a hazard under normal
operating conditions shall be guarded.
(ii) Guards shall be securely fastened.
(iii) Each guard shall be capable of supporting without
permanent distortion the weight of a 200-pound person unless
the guard is located where it is impossible for a person to step
on it.
1910.179(f) Brakes
(1) Brakes for hoists.
(i) Each independent hoisting unit of a crane shall be
equipped with at least one self-setting brake, hereafter referred
to as a holding brake, applied directly to the motor shaft or
some part of the gear train.
(ii) Each independent hoisting unit of a crane, except
worm-geared hoists, the angle of whose worm is such as to
prevent the load from accelerating in the lowering direction
shall, in addition to a holding brake, be equipped with control
braking means to prevent overspeeding.
(2) Holding brakes.
(i) Holding brakes for hoist motors shall have not less
than the following percentage of the full load hoisting torque
at the point where the brake is applied.
{a} 125 percent when used with a control braking means
other than mechanical.
{b} 100 percent when used in conjunction with a me-
chanical control braking means.
{c} 100 percent each if two holding brakes are provided.
(ii) Holding brakes on hoists shall have ample thermal
capacity for the frequency of operation required by the service.
(iii) Holding brakes on hoists shall be applied automati-
cally when power is removed.
(iv) Where necessary holding brakes shall be provided
with adjustment means to compensate for wear.
(v) The wearing surface of all holding-brake drums or
discs shall be smooth.
(vi) Each independent hoisting unit of a crane handling
hot metal and having power control braking means shall be
equipped with at least two holding brakes.
(3) Control braking means.
(i) A power control braking means such as regenerative,
dynamic or countertorque braking, or a mechanically con-
trolled braking means shall be capable of maintaining safe
lowering speeds of rated loads.
(ii) The control braking means shall have ample thermal
capacity for the frequency of operation required by service.
(4) Brakes for trolleys and bridges.
(i) Foot-operated brakes shall not require an applied force
of more than 70 pounds to develop manufacturers rated brake
torque.
(ii) Brakes may be applied by mechanical, electrical,
pneumatic, hydraulic, or gravity means.
(iii) Where necessary brakes shall be provided with ad-
justment means to compensate for wear.
(iv) The wearing surface of all brake drums or discs shall
be smooth.
(v) All foot-brake pedals shall be constructed so that the
operators foot will not easily slip off the pedal.
(vi) Foot-operated brakes shall be equipped with auto-
matic means for positive release when pressure is released
from the pedal.
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1910.179(f) Brakes (contd)
(vii) Brakes for stopping the motion of the trolley or bridge
shall be of sufficient size to stop the trolley or bridge within a
distance in feet equal to 10 percent of full load speed in feet
per minute when traveling at full speed with full load.
(viii) If holding brakes are provided on the bridge or
trolleys, they shall not prohibit the use of a drift point in the
control circuit.
(ix) Brakes on trolleys and bridges shall have ample ther-
mal capacity for the frequency of operation required by the
service to prevent impairment of functions from overheating.
(5) Application of trolley brakes.
(i) On cab-operated cranes with cab on trolley, a trolley
brake shall be required as specified under paragraph (f)(4) of
this section.
(ii) A drag brake may be applied to hold the trolley in a
desired position on the bridge and to eliminate creep with the
power off.
(6) Application of bridge brakes.
(i) On cab-operated cranes with cab on bridge, a bridge
brake is required as specified under paragraph (f)(4) of this
section.
(ii) On cab-operated cranes with cab on trolley, a bridge
brake of the holding type shall be required.
(iii) On all floor, remote and pulpit-operated crane bridge
drives, a brake of noncoasting mechanical drive shall be provided.
1910.179(g) Electric equipment
(1) General.
(i) Wiring and equipment shall comply with subpart S of
this part.
(ii) The control circuit voltage shall not exceed 600 volts
for a.c. or d.c. current.
(iii) The voltage at pendant push-buttons shall not exceed
150 volts for a.c. and 300 volts for d.c.
(iv) Where multiple conductor cable is used with a sus-
pended pushbutton station, the station must be supported
in some satisfactory manner that will protect the electrical
conductors against strain.
(v) Pendant control boxes shall be constructed to prevent
electrical shock and shall be clearly marked for identification
of functions.
(2) Equipment.
(i) Electrical equipment shall be so located or enclosed
that live parts will not be exposed to accidental contact under
normal operating conditions.
(ii) Electric equipment shall be protected from dirt, grease,
oil, and moisture.
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(iii) Guards for live parts shall be substantial and so lo-
cated that they cannot be accidently deformed so as to make
contact with the live parts.
(3) Controllers.
(i) Cranes not equipped with spring-return controllers
or momentary contact pushbuttons shall be provided with
a device which will disconnect all motors from the line on
failure of power and will not permit any motor to be restarted
until the controller handle is brought to the off position, or
a reset switch or button is operated.
(ii) Lever operated controllers shall be provided with a
notch or latch which in the off position prevents the handle
from being inadvertently moved to the on position. An off
detent or spring return arrangement is acceptable.
(iii) The controller operating handle shall be located
within convenient reach of the operator.
(iv) As far as practicable, the movement of each controller
handle shall be in the same general directions as the resultant
movements of the load.
(v) The control for the bridge and trolley travel shall be
so located that the operator can readily face the direction of
travel.
(vi) For floor-operated cranes, the controller or control-
lers if rope operated, shall automatically return to the off
position when released by the operator.
(vii) Pushbuttons in pendant stations shall return to the
off position when pressure is released by the crane operator.
(viii) Automatic cranes shall be so designed that all mo-
tions shall failsafe if any malfunction of operation occurs.
(ix) Remote-operated cranes shall function so that if the
control signal for any crane motion becomes ineffective the
crane motion shall stop.
(4) Resistors.
(i) Enclosures for resistors shall have openings to provide
adequate ventilation, and shall be installed to prevent the ac-
cumulation of combustible matter too near to hot parts.
(ii) Resistor units shall be supported so as to be as free as
possible from vibration.
(iii) Provision shall be made to prevent broken parts or
molten metal falling upon the operator or from the crane.
(5) Switches.
(i) The power supply to the runway conductors shall be
controlled by a switch or circuit breaker located on a fixed
structure, accessible from the floor, and arranged to be locked
in the open position.
(ii) On cab-operated cranes a switch or circuit breaker
of the enclosed type, with provision for locking in the open
position, shall be provided in the leads from the runway con-
ductors. A means of opening this switch or circuit breaker
shall be located within easy reach of the operator.
1910.179(f) Brakes (contd)
(iii) On floor-operated cranes, a switch or circuit breaker of
the enclosed type, with provision for locking in the open posi-
tion, shall be provided in the leads from the runway conductors.
This disconnect shall be mounted on the bridge or footwalk
near the runway collectors. One of the following types of floor-
operated disconnects shall be provided:
{a} Nonconductive rope attached to the main disconnect
switch.
{b} An undervoltage trip for the main circuit breaker
operated by an emergency stop button in the pendant pushbut-
ton in the pendant pushbutton station.
{c} A main line contactor operated by a switch or push-
button in the pendant pushbutton station.
(iv) The hoisting motion of all electric traveling cranes
shall be provided with an overtravel limit switch in the hoist-
ing direction.
(v) All cranes using a lifting magnet shall have a magnet
circuit switch of the enclosed type with provision for locking
in the open position. Means for discharging the inductive load
of the magnet shall be provided.
(6) Runway conductors. Conductors of the open type mount-
ed on the crane runway beams or overhead shall be so located
or so guarded that persons entering or leaving the cab or crane
footwalk normally could not come into contact with them.
(7) Extension lamps. If a service receptacle is provided in
the cab or on the bridge of cab-operated cranes, it shall be a
grounded three-prong type permanent receptacle, not exceed-
ing 300 volts.
1910.179(h) Hoisting equipment
(1) Sheaves.
(i) Sheave grooves shall be smooth and free from surface
defects which could cause rope damage.
(ii) Sheaves carrying ropes which can be momentarily
unloaded shall be provided with close-fitting guards or other
suitable devices to guide the rope back into the groove when
the load is applied again.
(iii) The sheaves in the bottom block shall be equipped
with close-fitting guards that will prevent ropes from becom-
ing fouled when the block is lying on the ground with ropes
loose.
(iv) Pockets and flanges of sheaves used with hoist chains
shall be of such dimensions that the chain does not catch or
bind during operation.
(v) All running sheaves shall be equipped with means for
lubrication. Permanently lubricated, sealed and/or shielded
bearings meet this requirement.
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(2) Ropes.
(i) In using hoisting ropes, the crane manufacturers
recommendation shall be followed. The rated load divided
by the number of parts of rope shall not exceed 20 percent of
the nominal breaking strength of the rope.
(ii) Socketing shall be done in the manner specified by
the manufacturer of the assembly.
(iii) Rope shall be secured to the drum as follows:
{a} No less than two wraps of rope shall remain on the
drum when the hook is in its extreme low position.
{b} Rope end shall be anchored by a clamp securely
attached to the drum, or by a socket arrangement approved
by the crane or rope manufacturer.
(iv) Eye splices. [Reserved]
(v) Rope clips attached with U-bolts shall have the U-
bolts on the dead or short end of the rope. Spacing and num-
ber of all types of clips shall be in accordance with the clip
manufacturers recommendation. Clips shall be drop-forged
steel in all sizes manufactured commercially. When a newly
installed rope has been in operation for an hour, all nuts on
the clip bolts shall be retightened.
(vi) Swaged or compressed fittings shall be applied as
recommended by the rope or crane manufacturer.
(vii) Wherever exposed to temperatures, at which fiber
cores would be damaged, rope having an independent wire
rope or wire-strand core, or other temperature-damage resis-
tant core shall be used.
(viii) Replacement rope shall be the same size, grade,
and construction as the original rope furnished by the crane
manufacturer, unless otherwise recommended by a wire rope
manufacturer due to actual working condition requirements.
(3) Equalizers. If a load is supported by more than one part
of rope, the tension in the parts shall be equalized.
(4) Hooks. Hooks shall meet the manufacturers recom-
mendations and shall not be overloaded.
1910.179(i) Warning device
Except for floor-operated cranes a gong or other effective
warning signal shall be provided for each crane equipped
with a power traveling mechanism.
1910.179(j) Inspection
(1) Inspection classification.
(i) Initial inspection. Prior to initial use all new and al-
tered cranes shall be inspected to insure compliance with the
provisions of this section.
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1910.179(j) Inspection (contd)
(ii) Inspection procedure for cranes in regular service is
divided into two general classifications based upon the inter-
vals at which inspection should be performed. The intervals in
turn are dependent upon the nature of the critical components
of the crane and the degree of their exposure to wear, dete-
rioration, or malfunction. The two general classifications are
herein designated as frequent and periodic with respective
intervals between inspections as defined below:
{a} Frequent inspection Daily to monthly intervals.
{b} Periodic inspection 1 to 12-month intervals.
(2) Frequent inspection. The following items shall be
inspected for defects at intervals as defined in paragraph (j)
(1)(ii) of this section or as specifically indicated, including
observation during operation for any defects which might
appear between regular inspections. All deficiencies such as
listed shall be carefully examined and determination made as
to whether they constitute a safety hazard:
(i) All functional operating mechanisms for maladjust-
ment interfering with proper operation. Daily.
(ii) Deterioration or leakage in lines, tanks, valves, drain
pumps, and other parts of air or hydraulic systems. Daily.
(iii) Hooks with deformation or cracks. Visual inspection
daily; monthly inspection with a certification record which
includes the date of inspection, the signature of the person
who performed the inspection and the serial number, or other
identifier, of the hook inspected. For hooks with cracks or hav-
ing more than 15 percent in excess of normal throat opening
or more than 10 degrees twist from the plane of the unbent
hook refer to paragraph (l)(3)(iii)(a) of this section.
(iv) Hoist chains, including end connections, for excessive
wear, twist, distorted links interfering with proper function,
or stretch beyond manufacturers recommendations. Visual
inspection daily; monthly inspection with a certification re-
cord which includes the date of inspection, the signature of
the person who performed the inspection and an identifier of
the chain which was inspected.
(v) [Reserved]
(vi) All functional operating mechanisms for excessive
wear of components.
(vii) Rope reeving for noncompliance with manufacturers
recommendations.
2012 CIA, Inc. Illegal to reproduce without written permission.
(3) Periodic inspection. Complete inspections of the crane
shall be performed at intervals as generally defined in para-
graph (j)(1)(ii)(b) of this section, depending upon its activ-
ity, severity of service, and environment, or as specifically
indicated below. These inspections shall include the require-
ments of paragraph (j)(2) of this section and in addition, the
following items. Any deficiencies such as listed shall be care-
fully examined and determination made as to whether they
constitute a safety hazard:
(i) Deformed, cracked, or corroded members.
(ii) Loose bolts or rivets.
(iii) Cracked or worn sheaves and drums.
(iv) Worn, cracked or distorted parts such as pins, bear-
ings, shafts, gears, rollers, locking and clamping devices.
(v) Excessive wear on brake system parts, linings, pawls,
and ratchets.
(vi) Load, wind, and other indicators over their full range,
for any significant inaccuracies.
(vii) Gasoline, diesel, electric, or other powerplants for
improper performance or noncompliance with applicable
safety requirements.
(viii) Excessive wear of chain drive sprockets and exces-
sive chain stretch.
(ix) [Reserved]
(x) Electrical apparatus, for signs of pitting or any deterio-
ration of controller contactors, limit switches and pushbutton
stations.
(4) Cranes not in regular use.
(i) A crane which has been idle for a period of 1 month
or more, but less than 6 months, shall be given an inspection
conforming with requirements of paragraph (j)(2) of this sec-
tion and paragraph (m)(2) of this section before placing in
service.
(ii) A crane which has been idle for a period of over 6
months shall be given a complete inspection conforming with
requirements of paragraphs (j)(2) and (3) of this section and
paragraph (m)(2) of this section before placing in service.
(iii) Standby cranes shall be inspected at least semi-
annually in accordance with requirements of paragraph (j)
(2) of this section and paragraph (m)(2) of this section.
1910.179(k) Testing
(1) Operational tests.
(i) Prior to initial use all new and altered cranes shall be
tested to insure compliance with this section including the
following functions:
{a} Hoisting and lowering.
{b} Trolley travel.
38
1910.179(k) Testing (contd)
{c} Bridge travel.
{d} Limit switches, locking and safety devices.
(ii) The trip setting of hoist limit switches shall be de-
termined by tests with an empty hook traveling in increasing
speeds up to the maximum speed. The actuating mechanism of
the limit switch shall be located so that it will trip the switch,
under all conditions, in sufficient time to prevent contact of the
hook or hook block with any part of the trolley.
(2) Rated load test. Test loads shall not be more than 125
percent of the rated load unless otherwise recommended by
the manufacturer. The test reports shall be placed on file where
readily available to appointed personnel.
1910.179 (l) Maintenance
(1) Preventive maintenance. A preventive maintenance
program based on the crane manufacturers recommendations
shall be established.
(2) Maintenance procedure.
(i) Before adjustments and repairs are started on a crane
the following precautions shall be taken:
{a} The crane to be repaired shall be run to a location
where it will cause the least interference with other cranes
and operations in the area.
{b} All controllers shall be at the off position.
{c} The main or emergency switch shall be open and
locked in the open position.
{d} Warning or out of order signs shall be placed
on the crane, also on the floor beneath or on the hook where
visible from the floor.
{e} Where other cranes are in operation on the same
runway, rail stops or other suitable means shall be provided
to prevent interference with the idle crane.
(ii) After adjustments and repairs have been made the
crane shall not be operated until all guards have been rein-
stalled, safety devices reactivated and maintenance equipment
removed.
(3) Adjustments and repairs.
(i) Any unsafe conditions disclosed by the inspection re-
quirements of paragraph (j) of this section shall be corrected
before operation of the crane is resumed. Adjustments and
repairs shall be done only by designated personnel.
(ii) Adjustments shall be maintained to assure correct
functioning of components. The following are examples:
{a} All functional operating mechanisms.
{b} Limit switches.
{c} Control systems.
{d} Brakes.
{e} Power plants.
(iii) Repairs or replacements shall be provided promptly
as needed for safe operation. The following are examples:
{a} Crane hooks showing defects described in para-
graph (j)(2)(iii) of this section shall be discarded. Repairs by
welding or reshaping are not generally recommended. If such
repairs are attempted they shall only be done under competent
supervision and the hook shall be tested to the load require-
ments of paragraph (k)(2) of this section before further use.
{b} Load attachment chains and rope slings showing
defects described in paragraph (j)(2) (iv) and (v) of this sec-
tion respectively.
{c} All critical parts which are cracked, broken, bent,
or excessively worn.
{d} Pendant control stations shall be kept clean and
function labels kept legible.
1910.179(m) Rope inspection
(1) Running ropes. A thorough inspection of all ropes shall
be made at least once a month and a certification record which
includes the date of inspection, the signature of the person
who performed the inspection and an identifier for the ropes
which were inspected shall be kept on file where readily
available to appointed personnel. Any deterioration, result-
ing in appreciable loss of original strength, shall be carefully
observed and determination made as to whether further use
of the rope would constitute a safety hazard. Some of the
conditions that could result in an appreciable loss of strength
are the following:
(i) Reduction of rope diameter below nominal diameter
due to loss of core support, internal or external corrosion, or
wear of outside wires.
(ii) A number of broken outside wires and the degree of
distribution or concentration of such broken wires.
(iii) Worn outside wires.
(iv) Corroded or broken wires at end connections.
(v) Corroded, cracked, bent, worn, or improperly applied
end connections.
(vi) Severe kinking, crushing, cutting, or unstranding.
(2) Other ropes. All rope which has been idle for a period
of a month or more due to shutdown or storage of a crane
on which it is installed shall be given a thorough inspection
before it is used. This inspection shall be for all types of
deterioration and shall be performed by an appointed person
whose approval shall be required for further use of the rope.
A certification record shall be available for inspection which
includes the date of inspection, the signature of the person
who performed the inspection and an identifier for the rope
which was inspected.
39 2012 CIA, Inc. Illegal to reproduce without written permission.
 (4) Hoist limit switch.
1910.179(n) Handling the load (i) At the beginning of each operators shift, the upper
limit switch of each hoist shall be tried out under no load.
(1) Size of load. The crane shall not be loaded beyond its Extreme care shall be exercised; the block shall be inched
rated load except for test purposes as provided in paragraph into the limit or run in at slow speed. If the switch does not
(k) of this section. operate properly, the appointed person shall be immediately
(2) Attaching the load. notified.
(i) The hoist chain or hoist rope shall be free from kinks (ii) The hoist limit switch which controls the upper limit
or twists and shall not be wrapped around the load. of travel of the load block shall never be used as an operating
(ii) The load shall be attached to the load block hook by control.
means of slings or other approved devices.
(iii) Care shall be taken to make certain that the sling
clears all obstacles. 1910.179(o) Other requirements, general
(3) Moving the load.
(i) The load shall be well secured and properly balanced
(1) Ladders.
in the sling or lifting device before it is lifted more than a few
(i) The employer shall ensure that hands are free from
inches.
encumbrances while personnel are using ladders.
(ii) Before starting to hoist the following conditions shall
(ii) Articles which are too large to be carried in pockets
be noted:
or belts shall be lifted and lowered by hand line.
{a} Hoist rope shall not be kinked.
(2) Cabs.
{b} Multiple part lines shall not be twisted around each
(i) Necessary clothing and personal belongings shall be
other.
stored in such a manner as not to interfere with access or
{c} The hook shall be brought over the load in such a
operation.
manner as to prevent swinging.
(ii) Tools, oil cans, waste, extra fuses, and other neces-
(iii) During hoisting care shall be taken that:
sary articles shall be stored in the tool box, and shall not be
{a} There is no sudden acceleration or deceleration of
permitted to lie loose in or about the cab.
the moving load.
(3) Fire extinguishers. The employer shall ensure that
{b} The load does not contact any obstructions.
operators are familiar with the operation and care of fire
(iv) Cranes shall not be used for side pulls except when
extinguishers provided.
specifically authorized by a responsible person who has deter-
mined that the stability of the crane is not thereby endangered
and that various parts of the crane will not be overstressed.
(v) While any employee is on the load or hook, there shall
be no hoisting, lowering, or traveling.
(vi) The employer shall require that the operator avoid
carrying loads over people.
(vii) The operator shall test the brakes each time a load
approaching the rated load is handled. The brakes shall be
tested by raising the load a few inches and applying the brakes.
(viii) The load shall not be lowered below the point where
less than two full wraps of rope remain on the hoisting drum.
(ix) When two or more cranes are used to lift a load one
qualified responsible person shall be in charge of the opera-
tion. He shall analyze the operation and instruct all personnel
involved in the proper positioning, rigging of the load, and
the movements to be made.
(x) The employer shall ensure that the operator does not
leave his position at the controls while the load is suspended.
(xi) When starting the bridge and when the load or hook
approaches near or over personnel, the warning signal shall
be sounded.

2012 CIA, Inc. Illegal to reproduce without written permission.

40
 OSHA 1926 Subpart CC
Cranes and Derricks
1926.1400 Scope
(a) This standard applies to power-operated equipment,
when used in construction, that can hoist, lower and horizon-
tally move a suspended load. Such equipment includes, but
is not limited to: articulating cranes (such as knuckle-boom
cranes); crawler cranes; floating cranes; cranes on barges;
locomotive cranes; mobile cranes (such as wheel-mounted,
rough-terrain, all-terrain, commercial truck-mounted, and
boom truck cranes); multi-purpose machines when configured
to hoist and lower (by means of a winch or hook) and hori-
zontally move a suspended load; industrial cranes (such as
carry-deck cranes); dedicated pile drivers; service/ mechanic
trucks with a hoisting device; a crane on a monorail; tower
cranes (such as a fixed jib, i.e., hammerhead boom), luff-
ing boom and self-erecting); pedestal cranes; portal cranes;
overhead and gantry cranes; straddle cranes; sideboom cranes;
derricks; and variations of such equipment. However, items
listed in paragraph (c) of this section are excluded from the
scope of this standard.
(b) Attachments. This standard applies to equipment
included in paragraph (a) of this section when used with
attachments. Such attachments, whether crane-attached or
suspended include, but are not limited to: hooks, magnets,
grapples, clamshell buckets, orange peel buckets, concrete
buckets, drag lines, personnel platforms, augers or drills and
pile driving equipment.
(c) Exclusions. This subpart does not cover:
(1) Machinery included in paragraph (a) of this section
while it has been converted or adapted for a non-hoisting/
lifting use. Such conversions/adaptations include, but are not
limited to, power shovels, excavators and concrete pumps.
(2) Power shovels, excavators, wheel loaders, backhoes,
loader backhoes, track loaders. This machinery is also ex-
cluded when used with chains, slings or other rigging to lift
suspended loads.
(3) Automotive wreckers and tow trucks when used to
clear wrecks and haul vehicles.
(4) Digger derricks when used for augering holes for poles
carrying electric and telecommunication lines, placing and
removing the poles, and for handling associated materials to be
installed on or removed from the poles. Digger derricks used
in work subject to 29 CFR part 1926, subpart V, must comply
with 29 CFR 1910.269. Digger derricks used in construction
work for telecommunication service (as defined at 29 CFR
1910.268(s)(40)) must comply with 29 CFR 1910.268.
(5) Machinery originally designed as vehicle-mounted
aerial devices (for lifting personnel) and self-propelled elevat-
ing work platforms.
(6) Telescopic/hydraulic gantry systems.
(7) Stacker cranes.
(8) Powered industrial trucks (forklifts), except when
configured to hoist and lower (by means of a winch or hook)
and horizontally move a suspended load.
(9) Mechanics truck with a hoisting device when used
in activities related to equipment maintenance and repair.
(10) Machinery that hoists by using a come-a-long or
chainfall.
(11) Dedicated drilling rigs.
(12) Gin poles when used for the erection of communica-
tion towers.
(13) Tree trimming and tree removal work.
(14) Anchor handling or dredge-related operations with
a vessel or barge using an affixed A-frame.
(15) Roustabouts.
(16) Helicopter cranes.
(17) Material Delivery
(i) Articulating/knuckle-boom truck cranes that deliver
material to a construction site when used to transfer materi-
als from the truck crane to the ground, without arranging the
materials in a particular sequence for hoisting.
(ii) Articulating/knuckle-boom truck cranes that deliver
material to a construction site when the crane is used to trans-
fer building supply sheet goods or building supply packaged
materials from the truck crane onto a structure, using a fork/
cradle at the end of the boom, but only when the truck crane
is equipped with a properly functioning automatic overload
prevention device. Such sheet goods or packaged materials
include, but are not limited to: sheets of sheet rock, sheets
of plywood, bags of cement, sheets or packages of roofing
shingles, and rolls of roofing felt.
41 2012 CIA, Inc. Illegal to reproduce without written permission.
1926.1400 Scope (contd)

(iii) This exclusion does not apply when:

(A) The articulating/knuckle-boom crane is used to
hold, support or stabilize the material to facilitate a construc-
tion activity, such as holding material in place while it is
attached to the structure;
(B) The material being handled by the articulating/
knuckle-boom crane is a prefabricated component. Such
prefabricated components include, but are not limited to:
precast concrete members or panels, roof trusses (wooden,
cold-formed metal, steel, or other material), prefabricated
building sections such as, but not limited to: floor panels, wall
panels, roof panels, roof structures, or similar items;
(C) The material being handled by the crane is a
structural steel member (for example, steel joists, beams, col-
umns, steel decking (bundled or unbundled) or a component
of a systems-engineered metal building (as defined in 29 CFR
1926 subpart R).
(D) The activity is not specifically excluded under
1400(c)(17)(i) and (ii).
(d) All sections of this subpart CC apply to the equipment
covered by this standard unless specified otherwise.
(e) The duties of controlling entities under this subpart
include, but are not limited to, the duties specified in
1926.1402(c), 1926.1402(e) and 1926.1424(b).
(f) Where provisions of this standard direct an operator,
crew member, or other employee to take certain actions, the
employer must establish, effectively communicate to the rel-
evant persons, and enforce, work rules to ensure compliance
with such provisions.
(g) For work covered by subpart V of this part, compliance
with 29 CFR 1910.269(p) is deemed compliance with
1926.1407 through 1926.1411.
(h) Section 1926.1402 does not apply to cranes designed
for use on railroad tracks, when used on railroad tracks that
are part of the general railroad system of transportation that is
regulated pursuant to the Federal Railroad Administration un-
der 49 CFR part 213, and that comply with applicable Federal
Railroad Administration requirements. See 1926.1402(f)
.

2012 CIA, Inc. Illegal to reproduce without written permission.

42
 OSHA 1926.1438

Overhead & Gantry Cranes

(ii) The following portions of 1910.179:

1926.1438 Overhead & gantry cranes (A) Paragraphs (b)(5),(6),(7); (e)(1), (3),(5),(6); (f)
(1),(4); (g); (h)(1),(3); (k); and (n) of 1910.179.
(a) Permanently installed overhead and gantry cranes. The (B) The definitions in 1910.179(a) except for hoist
requirements of 1910.179, except for 1910.179(b)(1), and and load. For those words, the definitions in 1926.1401
not the requirements of this subpart CC, apply to the follow- apply.
ing equipment when used in construction and permanently (C) Section 1910.179(b)(2), but only where the
installed in a facility: overhead and gantry cranes, including equipment identified in paragraph (b)(1) of this section (
semigantry, cantilever gantry, wall cranes, storage bridge 1926.1438) was manufactured before September 19, 2001.
cranes, and other having the same fundamental characteristics.
(iii) For equipment manufactured on or after September
(b) Overhead and gantry cranes that are not permanently
19, 2001, the following sections of ASME B30.2-2005 (incor-
installed in a facility.
(1) This paragraph applies to the following equipment porated by reference, see 1926.6) apply: 2-1.3.1; 2-1.4.1;
when used in construction and not permanently installed in 2-1.7.2; 2-1.8.2; 2-1.9.1; 2-1.9.2; 2-1.11; 2-1.12.2; 2-1.13.7;
a facility: overhead and gantry cranes, including semigantry, 2-1.14.2, 2-1.14.3; 2-1.14.5; 2-1.15; 2-2.2.2; 2-3.2.1.1. In ad-
cantilever gantry, wall cranes, storage bridge cranes, launch- dition, 2-3.5 applies, except in 2-3.5.1(b), 29 CFR 1910.147
ing gantry cranes, and similar equipment having the same is substituted for ANSI Z244.1.
fundamental characteristics, irrespective of whether it travels
on tracks, wheels or other means.
(2) The following requirements apply to equipment
identified in paragraph (b)(1) of this section:
(i) Sections 1926.1400 through 1926. 1414;
1926.1417 through 1926.1425; 1926.1426(d), 1926.1427
through 1926.1434; 1926.1437, 1926.1439, and
1926.1441.

43 2012 CIA, Inc. Illegal to reproduce without written permission.

 Applicable ASME Standards for
Inspecting Overhead Cranes

ASME B30.2
(2011)
Overhead and Gantry Cranes:
Top Running Bridge, Single or Multiple Girder,
Top Running Trolley Hoist

Copied by permission.
Note: pages 45-46 are an excerpt of the above standard. Revised 1.25.12
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2012 CIA, Inc. Illegal to reproduce without written permission.
44
 ASME B30.2 (2011)
(Applicable items not covered by OSHA 1910.179)
Chapter 2-1
General Construction and Installation
Section 2-1.9: Rail Sweeps
2-1.9.2 Trolley Rail Sweeps
(a)Trolley truck rail sweeps should be provided in front of
the leading wheels on both ends of the trolley end truck.
(b) The rail sweep shall clear the rail of objects on the
bridge which, if they came into contact between the wheel
and rail, could cause damage to the wheel or derail the wheel.
(1) Clearance between the top surface of the rail head and
the bottom of the sweep should not exceed 3/16 in. (5 mm).
(2) The sweep shall extend below the top surface of the
rail head, for distance not less than 50% of the thickness of
the rail head, on both sides of the rail head.
(3) Clearance between the side surface of the rail head
and the side of the sweep which extends below the top sur-
face of the rail head should be equal to crane float plus 3/16
in. (5 mm).
Section 2-1.11: Truck Frame Drop
Means shall be provided to limit the drop of bridge and
trolley truck frames to 1 in. (25mm) in case of wheel, axle,
or bearing breakage.
Section 2-1.13: Electrical Equipment
2-1.13.7 Lifting Magnets
(a) A crane for use with a lifting magnet shall have a sepa-
rate circuit switch of the enclosed type with provision for
locking in the open (off) position. The magnet disconnect
switch shall be connected on the line side (power supply
side) of the crane disconnect switch.
(b) Means shall be provided for discharging the inductive
load of a lifting magnet.
(c) Indication or signal lights should be provided to indi-
cate that power to a lifting magnet is on or off. These lights,
if used, shall be visible to the crane operator and to persons
on the floor.
(d) For remote-operated crane, the loss of the remote sig-
nal shall not result in demagnetizing the lifting magnet.
45
Chapter 2-2
Inspection and Testing
Section 2-2.2: Rope Inspection
2-2.3.2 Load Test
(a) New, reinstalled, altered, repaired, and modified cranes
should be load tested prior to initial use, as determined by a
qualified person.
(b) Load testing of altered, repaired, and modified cranes
may be limited to the functions affected by the alteration,
repair, or modification, as determined by a qualified person.
(c) The replacement of load chain and rope is specifically
excluded from this load test; however, an operational test of
the hoist shall be made in accordance with para. 2-2.3.1 prior
to putting the crane back in service.
(d) If a load test is conducted, the load shall be not less
than 100% of the rated load of the crane or hoist(s), which-
ever governs; or more than 125% of the rated load of the
crane or hoist(s), whichever governs; unless otherwise rec-
ommended by the manufacturer or a qualified person.
(e) If a load test is conducted, the person conducting the
load test shall prepare a written report of the load sustained
during the test and the operations performed during the test.
Reports shall be placed on file.
(f) If a load test is conducted, operations shall be performed
as outlined below or as modified by a qualified person.
(1) Hoist the test load a distance to ensure that the load
is supported by the crane and held by the hoist brake(s).
(2) Transport the test load by means of the trolley for the
full length of the bridge.
(3) Transport the load by means of the bridge for the
full length of the runway in one direction with the trolley as
close to the extreme right-hand end of the crane as practical,
and in the other direction with the trolley as close to the ex-
treme left-hand end of the crane as practical.
(4) Lower the test load, and stop and hold the load with
the brake(s).
2012 CIA, Inc. Illegal to reproduce without written permission.
 ASME B30.2 (2011)
(Applicable items not covered by OSHA 1910.179)
Chapter 2-4 B30.10-1.10.5 (2009) Removal Criteria (of Hooks)
Maintenance Training and Maintenance
Hooks shall be removed from service is damage such as the
following is visible and shall only be returned to service
Section 2-4.3: Rope Replacement and Maintenance when approved by a qualified person:
(d) cracks, nicks or gouges
2-4.3.1 Rope Replacement
(e) wear. Any wear exceeding 10% (or as recommended
(a) No precise rules can be given for determination of the
by the manufacturer) of the original section dimension of
exact time for rope replacement, since many variable factors
the hook or its load pin.
are involved. Once a rope reaches any one of the specified
(f) deformation. Any visibly apparent bend or twist from
removal criteria, it may be allowed to operate to the end of
the plane of the hook or its load pin.
the work shift, based on the judgment of a qualified person.
(g) throat opening. Any distortion causing an increase
The rope shall be replaced after the work shift, at the end
in throat opening exceeding 5%, not to exceed 1/4 inch
of the day, or at the latest time prior to the equipment being
(6mm) (or as recommended by the manufacturer).
used by the next work shift.
(h) inability to lock. Any self-locking hook that does not
(b) Removal criteria for rope replacement shall be as follows:
lock.
(1) in running ropes, twelve randomly distributed broken
(i) inability to latch (if required). Any damaged latch or
wires in one lay or four broken wires in one strand in one lay
malfunctioning latch that does not close the hoods throat.
(2) one outer wire broken at the contact point with the
core of the rope, which has worked its way out of the rope
structure and protrudes or loops out from the rope structure
(3) kinking, crushing, birdcaging, or any other damage
resulting in distortion of the rope structure
(4) apparent heat damage from any heat source
(5) reductions from nominal rope diameter greater than 5%
(c) Broken wire removal criteria cited in this Volume apply
only to wire rope operating on steel sheaves and drums. The
user shall contact the sheave, drum, or crane manufacturer,
or a qualified person, for broken wire removal criteria for
wire ropes operating on sheaves and drums made of material
other than steel.
(d) Attention shall be given to end connections. Upon
development of two broken wires adjacent to a socketed
end connection, the rope should be resocketed or replaced.
Resocketing shall not be attempted if the resulting rope
length will be insufficient for proper operation.
(e) Replacement rope shall have the same or higher min-
imum breaking force as the original rope specified by the
hoist manufacturer. Any deviation from the original size,
grade, or construction of the rope shall be specified by a rope
manufacturer, the crane or hoist manufacturer, or a qualified
person.

2012 CIA, Inc. Illegal to reproduce without written permission.

46
 Applicable ASME Standards for
Inspecting Overhead Cranes

ASME B30.11
(2010)
Monorails and Underhung Cranes

Copied by permission.
Note: pages 48-56 are an excerpt of the above standard. Revised 1.25.12.
To order complete ASME standards, call Crane Institute of America at (800) 832-2726 or visit craneinstitute.com

47 2012 CIA, Inc. Illegal to reproduce without written permission.

 ASME B30.11 (2010) Monorails and Underhung Cranes
Chapter 11-0
Scope, Definitions, and References
Section 11-0.1: Scope of B30.11
Volume B30.11 includes provisions that apply to the con-
struction, installation, operation, inspection, testing, and
maintenance of underhung cranes and monorail systems, track
sections, and load-carrying members, such as end trucks or
carriers (commonly called trolleys) that travel either on the
external or internal lower flange of a track section. The track
sections include single monorail track, crane bridge girders
and jib booms, all curves, switches, transfer devices, and lift
and drop sections. Provisions apply to both power-driven and
hand operated equipment in which the carriers are indepen-
dently controlled. Items within this scope may be referred to
as equipment.
Provisions for similar equipment used for a special purpose,
such as, but not limited to, nonvertical lifting service, lifting
a guided load, conveyor systems, including power and free
conveyors, and lifting or transporting personnel are not in-
cluded in this Volume.
Section 11-0.2: Definitions
normal operating conditions (of cab-operated cranes or car-
rier): conditions during which a crane or carrier is performing
functions within the scope of the original design. Under these
conditions, the operator is at the operating control devices and
no other person is on the crane or carrier.
normal operating conditions (of floor-operated cranes or
carrier): [same as above, except:] ...operator is at the operat-
ing control devices that are attached to the crane or carrier but
operated with the operator off the crane or carrier, and with
no person on the crane or carrier.
normal operating conditions (of remote-operated cranes or
carrier): [same as above, except:] ...operator is at the operating
control devices that are not attached to any part of the crane
or carrier.
2012 CIA, Inc. Illegal to reproduce without written permission.
Chapter 11-1
Construction and Installation
Section 11-1.1: Markings
11-1.1.1 Cranes
The rated load of the crane shall be marked on the crane, and
if the crane has more than one hoisting unit, each hoist shall
have its rated load marked on the hoist or its load block so that
the rated load marking shall be legible from the ground or floor.
The combined load on all hoists on the crane shall not exceed
the rated load of the crane.
11-1.1.2 Monorails
The rated load of the monorail should be marked on the
monorail. If the rated load is marked, it shall be legible from
the ground or floor. The combined load on all hoists on the
monorail shall not exceed the rated load of the monorail.
11-1.1.3 Hoists
The rated load of each hoist on a monorail shall be marked
in accordance with ASME B30.16
11-1.1.4 Trolleys
The rated load, the equipment manufacturers name, and
the model number or serial number shall be marked on each
trolley.
11-1.1.5 Warnings
(a) On floor-operated hoists, warnings are to be in accor-
dance with ASME B30.16.
(b) On cab-operated hoists, warnings for hoisting shall be
displayed in a readable position in the cab and in accordance
with ASME B30.16.
11-1.1.6 Controls
(a) Each control actuator shall be legibly marked to indicate
the function and direction of movement.
(b) In locations or areas where multiple systems are used by
nondedicated operators, the arrangement of control markings
for function and directions should be the same for all crane
and monorail systems in that location or area.
Section 11-1.2: Clearances
11-1.2.1 Clearances From Obstructions
In the design of crane or monorail systems, all factors that
influence clearances, such as wheel float, truss sag, and bridge
or carrier skewing, shall be considered.
48
 ASME B30.11 (2010) Monorails and Underhung Cranes
11-1.2.2 Clearances Between Parallel Cranes
(a) If the runways of two noninterlocking cranes are parallel
and there are no intervening walls or structures, there shall be
clearance provided and maintained between the two cranes.
(b) Where two cranes on parallel runways are designed for
interlocking transfer of the carrier(s), means shall be provided
to maintain clearance between the cranes so that the interlock-
ing ends of the crane girders do not strike each other when
passing, and so that the interlocking ends of the crane girders
do not strike a fixed interlocking crossover or spur track.
11-1.2.3 Clearances at Curves
Clearances shall be provided at the curves of a monorail
system to allow for the swing of the load when negotiating
the curve. The amount of this clearance shall be determined
by giving due consideration to the size, weight, and speed of
the carrier and the radius of the track curve.
Section 11-1.3: General Construction
11-1.3.1 Crane Runways and Monorail Tracks
(a) Crane runways, monorails, support systems, and sup-
porting structures shall be designed to withstand the loads
and forces imposed by the cranes and carriers.
(b) The structure shall be free from detrimental vibrations
under normal operating conditions.
(c) Track sections shall be installed with splices that ensure
proper alignment of the surface and sides of the load-carrying
flange.
(d) Runway tracks shall be spaced to be compatible with
the span and design of the crane.
(e) Where curves are required, special design will be necessary.
(f) Where change in elevation of the track is required, special
design will be necessary.
(g) Stops shall be provided at the ends of the carrier or
crane travel to prevent the carrier or crane from inadvertently
coming off the track or contacting an obstruction. Stops shall
be provided at open ends of tracks, such as at interlocking
crossovers, track spurs, track openers, and track switches.
Stops shall resist impact forces of a fully loaded carrier or
crane traveling at 50% of the rated full-load speed.
11-1.3.2 Track Supports
(a) Crane runways or monorail tracks shall be fastened to
a supporting structure by means of a support system.
(b) All support system components shall be designed to
withstand the loads and forces imposed by the cranes or
carriers. Hanger rods shall be installed plumb within the
manufacturers tolerances.
(c) Where multiple hanger rods are used at a suspension
point, consideration should be given to the unequal load
induced in the rods.
(d) Means shall be provided to restrain the track against
damaging lateral and longitudinal movement.
(e) Where the track is suspended from hanger rod assem-
blies, restraining means shall be provided to prevent the hanger
rod nuts from backing off the hanger rods.
(f) All track and track supports built after the issuance of this
Volume should conform to the minimum design parameters
as specified in ANSI MH27.1, ANSI MH27.2, the Manual
of Steel Construction, and the Specification for Aluminum
Structures, as applicable.
11-1.3.3 Cranes and Monorail Systems
All cranes and monorail systems built after the issuance of
this Standard should conform to the minimum design param-
eters as specified in The Manual of Steel Construction, CMAA
No. 74, ANSI MH27.1, or ANSI MH27.2, as applicable.
11-1.3.4 Welded Construction
All welding procedures and welding operator qualifications
to be used on load-sustaining members of cranes and mono-
rail systems shall conform to ANSI/AWS D14.1. Where field
welding of track supports is done, welding shall be done in
accordance with ANSI/AWS D1.1.
11-1.3.5 Modifications
The crane and monorail systems may be modified or rerated,
provided such modifications and the supporting structure
are analyzed by a qualified person or manufacturer of the
equipment. A rerated system or one whose load-supporting
components have been modified shall be tested in accordance
with Section 11-2.2. The new rated load shall be displayed in
accordance with Section 11-1.1.
Section 11-1.4: Track Switches, Track Openers, and
Interlocks
11-1.4.1 Track Switches
(a) All track switches shall be constructed and installed
to maintain alignment with incoming and outgoing tracks.
Control chains or ropes for hand-operated track switches,
push buttons for electrically operated track switches, and
operator-controlled valves for pneumatic or hydraulically
operated track switches shall be located within reach of the
operator.
(b) Stops shall be provided as an integral part of the switch
to protect the end of an incoming track when the switch track
is not aligned with the incoming track.
(c) Track switches should not be shifted with a carrier on the
movable track. Means shall be provided to prevent a carrier on
the movable track from running off the movable track when it
is not aligned with an outgoing track.
49 2012 CIA, Inc. Illegal to reproduce without written permission.
 ASME B30.11 (2010) Monorails and Underhung Cranes
(d) Means shall be provided to hold the movable frame in
a stationary position during passage of carriers through the
track switch.
(e) Electric baffles shall be provided on track switches and
incoming tracks on systems with cab control, automatic dis-
patch carriers, or molten material carriers as required in ANSI
Z241.2. Baffles shall prevent carrier contact with the end of an
incoming track when the switch track is not aligned with the
incoming track. Baffles shall also prevent the carrier or load
from interfering with a carrier or load on an adjacent track.
11-1.4.2 Track Openers
Stops shall be provided to prevent a crane from running off
either of the open ends of the track when the movable section
is not in alignment with the track.
11-1.4.3 Interlocks
(a) Interlocking mechanism for transfer and interlocking
cranes shall maintain alignment of the bridge girder(s) with
spur tracks, fixed transfer sections, or bridge girder(s) of
interlocking cranes operating on adjacent runways to permit
the transfer of a carrier from one to the other.
(b) Stops shall be an integral part of the interlock mecha-
nism. When bridge girders and spur tracks or fixed transfer
sections are not aligned and interlock mechanisms are en-
gaged, stops shall be in the open position to permit transfer of
a carrier from one to the other. When bridge girders and spur
tracks or fixed transfer sections are not aligned, or interlock
mechanisms are disengaged, stops shall be in the closed posi-
tion and shall prevent carriers from rolling off the end of spur
tracks, transfer sections, or bridge girders.
Section 11-1.5: Vertical Drop or Lift Sections
11-1.5.1 Carrier Passage
Vertical drop or lift sections shall maintain alignment of the
fixed tracks and the movable tracks to enable the passage of
a carrier.
11-1.5.2 Carrier Run Off Protection
Means shall be provided to prevent a carrier from running
off either end of the movable track when the movable track
is not in alignment with the fixed tracks.
11-1.5.3 Stops
Stops shall prevent a carrier from running off the open ends
of the fixed tracks when the movable track is not in alignment
with the fixed tracks.
2012 CIA, Inc. Illegal to reproduce without written permission.
50
11-1.5.4 Baffles
Electric baffles shall be provided on fixed and movable
tracks on systems with cab-operated carriers, automatic dis-
patch carriers, or molten material carriers. They shall limit
carrier travel when the movable track is not in alignment with
the fixed track. They shall also prevent the load from contact-
ing another load on the movable track.
Section 11-1.6: Cabs, Normal or Skeleton
11-1.6.1 Cab Location and Internal Arrangement
(a) The general arrangement of the cab and the location
of the control and protective equipment should be such that
all operating control devices are within reach of the operator
when facing the area to be served by the load block, or while
facing in the direction of travel of the cab.
(b) The arrangement of the cab should allow the operator to
view the load block in all positions. When physical arrange-
ments obscure the operators view, the operator shall be aided
by other means such as, but not limited to, closed circuit TV,
mirrors, radio, telephone, or a signal person.
(c) The cab shall be clear of all fixed structures within its
area of movement.
(d) The clearance of the cab above the working floor or
passageway should not be less than 7 ft (2.1 m), except when
operations require dimensions that are less. In this case, pre-
cautions shall be taken during the operation of the crane or
carrier to keep personnel and other obstructions clear of the
low overhead cab.
11-1.6.5 Fire Extinguisher
A portable fire extinguisher with a basic minimum extin-
guisher rating of 10 BC shall be installed in the cab.
Section 11-1.7: Guards and Lugs
11-1.7.1 Guards for Moving Parts
(a) Exposed moving parts, such as gears, set screws,
projecting keys, chains, chain sprockets, and reciprocating
components that constitute a hazard under normal operating
conditions, shall be guarded.
(b) Each guard shall be capable of supporting 200 lb. (90
kg), without permanent deformation, unless the guard is lo-
cated where it is not probable for a person to step on it.
11-1.7.2 Guards for Hoisting Ropes
(a) If it is possible for hoisting ropes to foul or chafe on
adjacent parts of the crane under normal operating conditions,
guards shall be installed to minimize damage to the rope.
(b) A guard shall be provided to prevent contact between
bridge or runway conductors and hoisting ropes, if under
normal operating conditions they can come into contact.
 ASME B30.11 (2010) Monorails and Underhung Cranes
11-1.7.3 Lugs
Means shall be provided to limit the drop of a bridge end
truck frame in case of wheel, axle, or load bar failure, and
shall be located on both sides of the track to provide central
loading of the track about the vertical axis if failure occurs.
Section 11-8: Brakes
11-1.8.1 Hoisting Brakes
Hoisting brakes shall conform to ASME B30.16.
11-1.8.2 Brakes for Bridge and Carrier Travel (Cab
Operated)
(a) Foot-operated brakes shall require an applied force of
not more than 70 lb (310 N) to develop rated brake torque.
(b) Brake pedal(s), latches, and levers should allow release
without the exertion of greater force than was used in applying
the brake.
(c) Foot-operated brakes shall be equipped with a means for
positive release when force is released from the pedal.
(d) The foot brake pedals shall be so located that they are
convenient to the operator.
(e) Brakes for stopping the motion of the carrier or bridge
shall have torque capability to stop the carrier or bridge within
a distance in ft (m) equal to 10% of the rated load speed in
ft/min (m/min) when traveling at full speed with rated load,
and with power off.
(f) All foot brake pedals shall be constructed so that the
operators foot will not readily slip off the pedal.
(g) If parking brakes are provided on the bridge or carrier, they
shall not prohibit the use of a drift point in the control circuit.
(h) Brakes shall have the thermal capacity for the frequency
of operation required by the service.
11-1.8.3 Brakes for Power-Operated Bridges and
Carriers (Floor- and Remote-Operated, Including
Skeleton Cab-Operated)
Brakes, if provided, shall meet the requirements of 11-
1.8.2(e), (g), and (h).
11-1.8.4 Application of Brakes
(a) On cap-operated cranes with cab on bridge, a bridge
brake shall be provided and shall meet the requirements of
para. 11-1.8.2.
(b) On cab-operated cranes with cab on carrier, carrier and
bridge brakes shall be provided and shall meet the require-
ments of para. 11-1.8.2
(c) On cab-operated carriers operating on a monorail, a
carrier brake(s) shall be provided and shall meet the require-
ments of para. 11-1.8.2.
51
(d) On all floor and remote-operated cranes or carriers,
a travel brake(s) is not required, provided that, in case of
power failure, the travel motion can be retarded and stopped
within the travel distance specified in para. 11-1.8.2(e). If this
requirement cannot be compiled with, a brake or noncoasting
mechanical drive shall be provided and shall meet the require-
ments of para. 11-1.8.3.
Section 11-1.9: Electrical Equipment
11-1.9.1 General
(a) Wiring and equipment shall comply with Article 610 of
ANSI/NFPA 70.
(b) The control circuit voltage shall not exceed 600 V for
AC or DC.
(c) The voltage at pendant push buttons shall not exceed
150 V for AC or 300 V for DC.
(d) Where multiple-conductor cable is used with a suspended
push-button station, the station shall be supported so that elec-
trical conductors are protected from strain.
(e) Pendant control stations shall be constructed to prevent
electrical shock. The push-button enclosure shall be at ground
potential and marked for identification of functions.
11-1.9.2 Equipment
(a) Electrical equipment shall be so located or enclosed that
live parts will not be exposed to inadvertent contact under
normal operating conditions.
(b) Live parts of electrical equipment shall be protected
from direct exposure to grease and oil, and should be protected
from dirt and moisture.
(c) Guards for live parts, if provided, shall be so located that
they cannot be accidentally deformed so as to make contact
with the live parts.
11-1.9.3 Controls
(a) Cab-Operated Controls
(1) Lever-operated manual controllers and master switch-
es shall be provided with an off-position notch or latch. A
spring return to the off position is acceptable.
(2) The operating handle for manual controller or master
switch shall be located within reach of the operator.
(3) The movement of the handle of each manual control-
ler or master switch should be in the same general direction
as the resultant movements of the load, except as shown in
Figs. 11-1.9.3-1 and 11-1.9.3-2.
(4) The arrangement of controllers or master switches
should conform to Figs. 11-1.9.3-1 and 11-1.9.3-2.
(b) Floor-Operated Controls
(1) For floor-operated cranes or carriers, the controller or
controllers, if rope operated, shall automatically return to the
off position when released.
2012 CIA, Inc. Illegal to reproduce without written permission.
 ASME B30.11 (2010) Monorails and Underhung Cranes
(2) Pendant push buttons that control motion shall return
to the off position when pressure is released by the operator.
(3) The arrangement of pendant push buttons should
conform to Fig. 11-1.9.3-3.
(c) Automatic and Remote Controls
(1) Automatic cranes or carriers shall be so designed that
operation of all motions shall be discontinued if the automatic
sequence control becomes ineffective. Completion of the last
command is permissible if power is available.
(2) Remote-operated cranes or carriers shall function
so that if the control signal for any crane or carrier motion
becomes ineffective, that crane or carrier motion shall stop.
Conversely, signals received from any source other than the
operating station (transmitter) shall not result in operation of
any motion of the crane or carrier.
(3) The arrangement of radio-controlled crane transmit-
ters should conform to Fig. 11-1.9.3-4.
11-1.9.4 Resistors (if Provided)
(a) Resistor units shall be supported to minimize vibration
effect.
(b) Provisions shall be made to prevent broken parts or
molten metal from falling upon the operator or from the crane
or carrier.
(c) If resistor enclosures are provided, the enclosures shall
be installed to prevent the accumulation of combustible matter.
11-1.9.5 Switches
(a) The electrical supply to runway or monorail conductors
shall be controlled by a switch or circuit breaker located on a
fixed structure, accessible from the floor, with provision for
being locked in an open position.
(b) On cab-operated cranes or carriers, a switch or circuit
breaker of the enclosed type, with provision for locking in
the open position, shall be provided in the leads from the
runway or monorail conductors. A means of opening this
device shall be located within reach of the operator from the
operating position. When the operator opens this switch or
circuit breaker, the electric brakes shall set.
(c) On floor- or remote-operated cranes, a disconnect device
of the enclosed type shall be provided in the leads from the
runway conductors. This device should be mounted on the
bridge near the runway collectors. There shall be provisions for
locking the device in the open position, unless the crane is the
only load on a lockable switch or circuit breaker that is located
in the general area of the crane. One of the following types
of floor- or remote-operated disconnects shall be provided:
(1) a nonconductive rope attached to the main disconnect
device on a floor-operated crane. If this is selected, the rope
shall be suspended adjacent to the operating ropes if manual
controllers are used, or near the pendant push-button station
if magnetic controls are used.
2012 CIA, Inc. Illegal to reproduce without written permission.
52
(2) an undervoltage trip for the main circuit breaker, oper-
ated by an emergency stop button accessible to the operator.
(3) a main line contactor operated by a switch or push
button accessible to the operator.
11-1.11 Warning Devices
On cab- and remote-operated cranes or carriers, an audible
or visual warning means shall be provided.
Chapter 11-2
Inspection and Testing
This Chapter establishes and defines the criteria for deter-
mining whether cranes, crane runways, monorail systems,
and support systems can be expected to perform as intended.
Section 11-2.1: Inspection
11-2.1.1 General
(a) There are five types of inspections required, each di-
rected toward a different set of circumstances. They are
(1) initial inspection
(2) functional test inspection
(3) frequent inspection
(4) periodic inspection
(5) inspection of equipment not in regular use
(b) In addition, the inspection and testing shall be based
on the recommendations in the equipment manufacturers
manual; and, when appropriate, recommendations by a quali-
fied person based upon review of the equipment application
and operation.
11-2.1.2 Initial Inspection
(a) An initial inspection is a visual and audible examination
of the crane, the runway, monorail systems, and the support
system by a designated person.
(b) New, reinstalled, altered, repaired, modified equipment,
and supporting structures shall be inspected by a designated
person prior to initial use to verify compliance with applicable
provisions of Section 11-2.1 of this Volume.
(c) Inspection of altered, repaired, and modified equipment
may be limited to the parts of the crane, runway, monorail
systems, or support system affected by the alteration, repair,
or modification, as determined by a qualified person.
(d) The equipment shall be tested in accordance with Sec-
tion 11-2.2 in addition to the inspection.
(e) Adjustments, repairs, or replacements necessary to
satisfy the requirements of this section shall be made in ac-
cordance with para. 11-4.2.4 prior to initial use.
ASME B30.11 (2010) Monorails and Underhung Cranes
Recommended Trolley Fit

Lubrication
fitting

Measure
clearance here
1/8 in. to 1/4 in.

General Note: To adjust for wider

Inside spacer washers Cross pin
flange widths, use additional
Spacer Washer Arrangement washers inside as required, in
equal numbers at each side of
(Minimum Flange Width Shown)
cross pin.

Recommended Trolley Wheel Configurations

Beam with Crown Tread Beam with Canted Flat Tread

Wheel (Preferred) Wheel (Acceptable)

Beam with Flat Tread

Wheel (Unacceptable)

Patented Rail with Flat Patented Rail with Crowned

Tread Wheel (Preferred) Tread Wheel (Acceptable)

53 2012 CIA, Inc. Illegal to reproduce without written permission.

 ASME B30.11 (2010) Monorails and Underhung Cranes
(f) Dated and signed inspection and test records shall be
maintained to provide the basis for continuing evaluation. Re-
cords should be kept where available to appointed personnel.
11-2.1.3 Functional Test Inspection
(a) A functional test inspection is a visual and audible oper-
ational examination of the equipment, and shall be conducted
at the beginning of each shift, or before the equipment is first
used during each shift, by the operator or a designated person.
In special applications, when the handling of a suspended load
is transferred from operator to operator at shift change, the
functional test inspection shall be performed when that lift is
completed.
(b) As a minimum, the following items shall be inspected
during performance of the functional test inspection:
(1) operational controls
(2) upper limit device(s) in accordance with ASME
B30.16
(3) chain or wire rope in accordance with ASME B30.16
(c) Adjustments, repairs, or replacements necessary to
satisfy requirements shall be made in accordance with para.
11-4.2.4 prior to initial use if the functional test inspection
reveals that there are items and conditions that do not comply
with the provisions.
(d) Deficiencies discovered during this inspection shall be
reported immediately to the supervisor or a designated person.
11-2.1.4 Frequent Inspection
(a) A frequent inspection is a visual and audible examination of
the equipment conducted by the operator or a designated person.
(b) Hoist inspection shall be in accordance with ASME
B30.16.
(c) Equipment shall be inspected at intervals dependent on
the use of the equipment as follows:
(1) normal service monthly
(2) heavy service weekly to monthly
(3) severe service daily to weekly
(d) As a minimum, the following items shall be inspected:
(1) operating mechanisms for proper operation, proper
adjustment, and unusual sounds; such as, but not limited to,
squeaking, grinding, grating, etc.
(2) upper limit device(s) in accordance with ASME
B30.16
(3) tanks, valves, pumps, lines, and other parts of air or
hydraulic systems for leakage
(4) hooks and latches, if used, in accordance with ASME
B30.10
(5) hook attachment and securing means
(6) warning device(s) for proper operation
(7) chain or wire rope in accordance with ASME B30.16
(8) placement of end stops
2012 CIA, Inc. Illegal to reproduce without written permission.
(e) A qualified person shall determine whether conditions
found during the inspection constitute a hazard and require a
more detailed inspection.
(f) Adjustments, repairs, or replacements shall be made,
as necessary, in accordance with para. 11-4.2.4.
(g) Deficiencies discovered during this inspection shall be
reported immediately to the supervisor or a designated person.
11-2.1.5 Periodic Inspection
(a) A periodic inspection is a visual and audible examination
of the equipment conducted by a designated person.
(b) Hoist inspection shall be in accordance with ASME
B30.16.
(c) Equipment shall be inspected at intervals dependent on
the use of the equipment as follows:
(1) normal service yearly
(2) heavy service semiannually
(3) severe service quarterly
(d) The inspection shall include, but is not limited to, the
following items.
(1) deformed, cracked, or corroded members; including
hangers and sway braces;
(2) loose bolts, nuts, or rivets;
(3) cracked or worn sheaves, drums, or chain sprockets;
(4) worn, cracked, or distorted parts such as pins, bearings,
wheels, shafts, gears, rollers, locking and clamping devices,
bumpers, switch baffles, interlock bolts, and end stops;
(5) hooks and latches, if used, in accordance with ASME
B30.10;
(6) hook attachment and securing means;
(7) excessive wear of brake system parts;
(8) excessive wear of chain drive sprockets and excessive
chain stretch;
(9) deterioration of motors, controllers, master switches,
contacts, limit device(s), and push-button stations;
(10) wind indicators for proper operation;
(11) travel limit devices for proper performance; Each
motion shall be inched or operated at low speed into the limit
device with no load on the crane;
(12) upper and lower limit device(s) in accordance with
ASME B30.16;
(13) warning device(s) for proper operation;
(14) chain or wire rope in accordance with ASME B30.16;
(15) function, instruction, warning and safety information
signs, labels, or plates for placement and legibility;
(16) operating mechanisms for proper operation, proper
adjustment, and unusual sounds; such as, but not limited to,
squeaking, grinding, grating, etc.;
(17) tanks, valves, pumps, lines, and other parts of air or
hydraulic systems for leakage;
(18) excessive wear of drive tires;
54
 ASME B30.11 (2010) Monorails and Underhung Cranes
(19) excessive wear or deformation of the lower load-
carrying flange of all track sections in the system, both straight
and curved;
(20) excessive wear of carrier (trolley) guide and drive
wheels;
(21) carrier adjustments and tolerances to manufacturer
specifications;
(e) A qualified person shall determine whether conditions
found during the inspection require further evaluation or dis-
assembly, or constitute a hazard that requires the equipment
to be taken out of service;
(f) Adjustments, repairs, or replacements shall be made,
as necessary, in accordance with para. 11-4.2.4;
(g) Dated and signed inspection and test records shall be
maintained to provide the basis for continuing evaluation. Re-
cords should be kept where available to appointed personnel.
11-2.1.6 Inspection of Cranes and Monorails Not
in Regular Use
(a) Equipment that has been idle for a period of 1 mo. or
more, but less than 1 yr, shall be inspected before being placed
into service in accordance with para. 11-2.1.4.
(b) Equipment that has been idle for a period of 1 yr or
more shall be inspected before being placed into service in
accordance with para. 11-2.1.5.
Section 11-2.2: Testing
11-2.2.1 Operational Tests
(a) New, reinstalled, altered, repaired, and modified cranes
and monorail systems shall be tested by a designated person
prior to initial use to confirm that the equipment performs in
compliance with the provisions of this Volume.
(b) Tests shall include, as applicable, the following functions:
(1) lifting and lowering (NOTE: Refer to ASME B30.16
for hoist test.)
(2) carrier travel
(3) bridge travel
(4) upper limit device(s) in accordance with ASME
B30.16
(5) travel-limiting devices
(6) locking and safety devices for interlocking mecha-
nisms, track switches, drop sections, and lift sections
(7) indicating devices, if provided
(c) Operational testing of altered, repaired, or modified
crane and monorail systems may be limited to the functions
affected by the alteration, repair, or modification, as deter-
mined by a qualified person.
55
11-2.2.2 Load Test
(a) New, reinstalled, altered, repaired and modified equip-
ment should be load tested prior to initial use as determined
by a qualified person.
(b) Load testing of altered, repaired and modified equip-
ment may be limited to the functions affected by the alteration,
repair, or modification, as determined by a qualified person.
(c) The replacement of load chain and rope is specifically
excluded from this load test; however, an operational test of
the hoist shall be made in accordance with ASME B30.16
prior to putting the crane or monorail system back in service.
(d) If a load test is conducted, the load shall be not less than
100% of the rated load of the crane or monorail system or more
than 125% of the rated load, unless otherwise recommended
by the manufacturer or a qualified person.
(e) If a load test is conducted, the person conducting the
load test shall prepare a written report of the load sustained
during the test and the operations performed during the test.
Reports shall be placed on file.
(f) If a load test is conducted for cranes, operations shall
be performed as outlined below or as modified by a qualified
person.
(1) Hoist the test load a distance to assure that the load is
supported by the crane and held by the hoist brake(s). (Note:
Refer to ASME B30.16 for hoist test.)
(2) Transport the test load by means of the carrier for the
full length of the bridge.
(3) Transport the test load by means of the bridge for the
full length of the runway in one direction with the carrier as
close to the extreme right-hand end of the crane as practical
and in the other direction with the carrier as close to the left-
hand end of the crane as practical. When cranes operate on
more than two runways (multiple-truck cranes), the crane
shall also transport the test load the full length of the runway
with the carrier positioned at each intermediate end truck.
(4) Lower the test load, stop and hold the load with the
brake(s).
(g) If a load test is conducted for monorail systems, opera-
tions shall be performed as outlined below or as modified by
a qualified person.
(1) Hoist the test load a distance to assure that the load is
supported by the equipment and held by the hoist brake(s).
(Note: Refer to ASME B30.16 for hoist test.)
(2) Transport the test load by means of the carrier for the
full length of the monorail system.
(3) Lower the test load, and stop and hold the load with
the brake(s).
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 ASME B30.11 (2010) Monorails and Underhung Cranes
(h) If a load test is conducted for jib crane systems, opera-
tions shall be performed as outlined below or as specified by
a qualified person.
(1) Hoist the test load a distance to ensure that the load
is supported by the equipment and held by the hoist brake(s).
(NOTE: Refer to ASME B30.16 for hoist test.)
(2) Transport the test load by means of the carrier for the
full length of the jib system.
(3) Rotate the jib throughout the full range of travel with the
test load applied at the maximum distance from the pivot point.
(4) Lower the test load, stop and hold the load with the
brake(s).
Chapter 11-3
Operator Training and Operation
Section 11-3.2 Training for Persons Other Than
Crane and Monorail System Operators
Other persons, such as, but not limited to, maintenance
personnel, test personnel, and inspectors, when it is necessary
to operate a crane or monorail system in the performance of
their duties, shall be trained in accordance with the training
requirements of this Volume for their duties.
Section 11-3.5 Signals
11-3.5.1 Standard Signals
Signals to the operator should be in accordance with
the standards prescribed in Fig. 11-3.3.4-1, unless voice
communication equipment (telephone, radio, or equiva-
lent) is utilized. Signals should be discernible or au-
dible at all times. Some special operations may re-
quire additions to, or modifications of, the basic signals.
Section 11-3.6 Miscellaneous
11-3.6.1 Cabs
(a) Necessary clothing and personal belongings shall be stored
in such a manner as to not interfere with access or operation.
(b) Tools, oil cans, and other necessary articles shall be
stored in a toolbox and shall not lie loose in or about the cab.
(c) Materials stored in cabs shall be limited to necessary items.
11-3.6.2 Fire Extinguishers
Operators shall be familiar with the operation and care of
fire extinguisher(s) provided.
Section 11-3.7 Equipment Lockout/Tagout
11-3.7.2 General
(a) A lockout/tagout policy and procedure shall be devel-
oped, documented, and implemented by the owner or user of
crane and monorail systems.
(b) The lockout/tagout policy and procedure shall comply
with the requirements of ASSE Z244.1.
(c) The policy shall include, but is not be limited to
(1) single-crane runways
(2) multiple-crane runways
(3) monorail systems
(4) cranes on an adjacent runway
(5) runway disconnecting means
(6) crane disconnecting means
(7) work to be done on the crane
(8) work to be done other than on a crane but within the
path of a crane where its movement creates a hazard.

11.3.5.2 Hand Signals

When hand signals are used, they should be posted con-
spicuously and should be as illustrated in Fig. 11-3.3-1.
(a) Cranes that are equipped with separately operated car-
riers present a problem and precautions should be taken to
establish ground person-to-crane operating signals.
(b) Crane carriers should be numbered with numerals large
enough so they are legible from the floor. Hoist load blocks
should have numbers applied on both sides of the block. Car-
riers should be numbered as follows:
(1) Carrier nearest the crane cab is designated as No. 1.
(2) Carrier away from the crane cab is designated as No. 2.

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56
 ASME B30.11 (2010) Monorails and Underhung Cranes

Applicable ASME Standards for

Inspecting Overhead Cranes

ASME B30.16
(2007)
Overhead Hoists (Underhung)

Copied by permission.
Note: pages 58-68 are an excerpt of the above standard. Revised 1.25.12
To order complete ASME standards, call Crane Institute of America at (800) 832-2726 or visit craneinstitute.com

57 2012 CIA, Inc. Illegal to reproduce without written permission.

 ASME B30.16 (2007) Overhead Hoists (Underhung)
Chapter 16-0
Scope, Definitions, and References
Section 16-0.1: Scope of B30.16
Volume B30.16 includes provisions that apply to the con-
struction, installation, operation, inspection, and maintenance
of hand chain operated chain hoists and electric and air pow-
ered chain and wire rope hoists used for, but not limited to,
vertical lifting and lowering of freely suspended, unguided,
loads which consist of equipment and materials.
Requirements for a hoist that is used for a special purpose,
such as, but not limited to, tensioning a load, non-vertical
lifting service, lifting a guided load, lifting personnel, or draw-
ing both the load and the hoist up or down the load chain or
rope when the hoist is attached to the load, are not included
in this volume.
Section 16-0.2: Definitions
abnormal operating conditions: conditions during which a
hoist is performing functions within the scope of the original
design.
service, normal: service that involves operation with randomly
distributed loads within the rated load limit, or uniform loads
less than 65% of rated load for not more than 15% of the
time for manually operated hoists, and 25% of the time for
electric- or air-powered hoists.
service, heavy: service that involves operation within the rated
load limit, which exceeds normal service.
service, severe: service that involves normal or heavy service
with abnormal operating conditions.
Chapter 16-1
Marking, Construction, and Installation
Section 16-1.1: Marking
16-1.1.1 Rated Load
The rated load of the hoist shall be marked on the hoist or
its load block and shall be legible from the ground or floor.
16-1.1.2 Controls
(a) Each control actuator of an electric- or air-powered hoist
shall be marked to indicate the direction of resultant motion.
(b) In locations or areas where multiple electric-powered or
air-powered hoists are used by non-dedicated hoist operators,
the arrangement of control actuator markings for direction of
motion on pendant push button stations and radio-controlled
transmitters should be the same for all hoists in that location
or area.
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58
16-1.1.3 Identification
The hoist shall be marked with manufacturers identification
information, on a plate or label attached to the hoist, or cast,
forged, or stamped on the hoist, as follows:
(a) Hand Chain Operated Hoist
(1) name of manufacturer
(2) manufacturers model or serial number
(b) Electric-Powered Hoist
(1) name of manufacturer
(2) manufacturers model or serial number
(3) voltage of AC or DC power supply and phase and
frequency of AC power supply
(4) circuit ampacity
(c) Air-Powered Hoist
(1) name of manufacturer
(2) manufacturers model or serial number
(3) rated air pressure
16-1.1.4 Warnings
(a) All hand chain operated hoists shall have affixed to the
hoist or load block, a label or labels displaying information
concerning operating procedures. The label or labels shall be
in compliance with ANSI Z535.4, and shall include cautionary
language against:
(1) lifting more than rated load;
(2) operating hoist with twisted, kinked, or damaged chain;
(3) operating damaged or malfunctioning hoist;
(4) lifting people;
(5) lifting loads over people;
(6) operating hoist with other than manual power;
(7) removing or obscuring label.
(b) All electric- or air-powered hoists shall have affixed to
the hoist, load block, or controls, a label or labels displaying
information concerning operating procedures. The label or
labels shall be in compliance with ANSI Z535.4, and shall
include cautionary language against:
(1) lifting more than rated load;
(2) operating hoist when load is not centered under hoist;
(3) operating hoist with twisted, kinked, or damaged chain
or rope;
(4) operating damaged or malfunctioning hoist;
(5) lifting people;
(6) lifting loads over people;
(7) operating a rope hoist with a rope that is not properly
seated in its groove;
(8) removing or obscuring label.
(c) A label shall be affixed on all electrical control enclo-
sures. The label shall be in compliance with ANSI Z535.4,
and shall include, but not be limited to, information such as:
(1) Disconnect power and lockout/tagout disconnecting
means before removing cover or servicing this equipment
(2) Do not operate without cover in place
 ASME B30.16 (2007) Overhead Hoists (Underhung)
Section 16-1.2 Construction
16-1.2.1 Mechanical Design
(a) The hoist and appurtenances shall be designed to with-
stand all stresses imposed under normal operating conditions
while handling loads within the rated load (capacity).
(b) Load suspension parts, except for roller load chain, of
hand chain operated hoists shall be designed so that the static
stress calculated for the rated load shall not exceed 25% of
the average ultimate material strength. Roller load chain shall
be designed so that the static stress calculated for the rated
load shall not exceed 25% of the minimum ultimate tensile
strength as stated in ASME B29.24.
(c) Load suspension parts, except for roller load chain,
of electric-powered or air-powered hoists shall be ASME
B30.162007 designed so that the static stress calculated for
the rated load shall not exceed 20% of the average ultimate
material strength. Roller load chain shall be designed so that
the static stress calculated for the rated load shall not exceed
20% of the minimum ultimate tensile strength as stated in
ASME 829.24.
(d) Power transmission parts shall be designed so that the
dynamic stress calculated for the rated load shall not exceed
the endurance limits established by the manufacturer.
(e) Modifications to upgrade, rerate, or modernize hoist
equipment shall be as authorized only by the original equip-
ment manufacturer or a qualified person.
(f) The hoist should be designed in accordance with ap-
plicable hoist design and performance standards.
Refer to ASME HST-1, ASME HST-2, ASME HST-4, ASME
HST-5, and ASME HST-6.
16-1.2.2 Electrical Design (Electric-Powered
Hoists only)
(a) Electrical construction shall comply with Article 610
of ANSI/NFPA 70.
(b) Unless otherwise specified, control enclosures shall be
NEMA Type 1, general purpose for indoor application in ac-
cordance with ANSI/NEMA No. ICS6.
(c) Electric equipment shall be so located or enclosed that
live parts will not be exposed to inadvertent contact under
normal operating conditions.
(d) Enclosures for resistors (if required) shall provide means
for heat dissipation and shall be installed to minimize the ac-
cumulation of combustible matter. Provisions shall be made
to prevent broken resistor parts or molten metal from falling
onto operator, other personnel, or combustible materials.
16-1.2.3 Controls (Electric- or Air-Powered Hoists
Only)
(a) Controls, except in automatic cycling operation, shall
return to the off position when released, and hook motion
shall stop.
(b) Reversing contactor of electric-powered hoists shall be
mechanically or electrically interlocked to prevent line-to-line
faults.
(c) The voltage at pendant push-button station of electric-
powered hoists shall not exceed 150 V for AC or 300 V for DC.
(d) A pendant station shall be supported in a manner that
will protect the electrical conductors or air hoses against
strain. Any pendant station that might present a hazard to the
operator, if a ground fault occurs, shall be grounded.
16-1.2.4 Rope Sheaves (Electric- or Air-Powered
Hoists Only)
(a) The grooves shall be free from surface conditions of
damage that could cause accelerated wear or damage to the
rope. The cross-sectional radius at the bottom of the groove
should be such as to form a close-fitting saddle for the size of
rope used. The sides of the groove shall be tapered outward
and rounded at the rim to facilitate entrance of the rope into the
groove. Flange rims shall run true about the axis of rotation.
(b) Sheaves shall be so mounted as to guard against rope
jamming during normal operating conditions.
(c) All running sheave bearings except permanently lubri-
cated bearings should be equipped with means for lubrication.
16-1.2.5 Rope Drum (Electric- or Air-Powered
Hoists Only)
Rope drums shall be grooved except when the hoist is
provided by the manufacturer for a special application. This
requirement does not preclude the use of multiple layer spool-
ing. The grooves shall be free from surface conditions or
damage that could cause accelerated wear or damage to the
rope. The cross-sectional radius at the bottom of the groove
should form a close-fitting saddle for the size of rope used.
16-1.2.6 Ropes (Electric- or Air-Powered Hoists
Only)
(a) The hoisting ropes shall be of a construction recom-
mended for hoist service. The rated load divided by the
number of parts (lines) of rope shall not exceed 20% of the
minimum breaking strength of the rope. When rope and rope
core may be exposed to an environmental condition under
which rope or core would be damaged, a rope and core hav-
ing resistance to the conditions shall be used.
(b) Socketing shall be done in a manner recommended by
the rope of fitting manufacturer or a qualified person.
(c) The rope ends shall be attached to the hoist in a manner to
prevent disengagement throughout rated hook travel. No less
than two wraps of rope shall remain on each anchorage of the
hoist drum when the hook is in its extreme low position unless
a lower limit device is provided, in which case no less than
one wrap shall remain on each anchorage of the hoist drum.
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 ASME B30.16 (2007) Overhead Hoists (Underhung)
(d) Eye splices shall be made in a manner recommended
by the rope or hoist manufacturer or a qualified person. Rope
thimbles should be used in the eye.
(e) Wire rope clips shall be drop-forged steel of the single
saddle (U-bolt) or double saddle type clip. Malleable cast
iron clips shall not be used. For spacing, number of clips,
and torque values, refer to the clip manufacturers recom-
mendation. Wire rope clips attached with U-bolts shall have
the U-bolt over the dead end of the rope and the live rope
resting in the clip saddle. Clips shall be tightened evenly to
the recommended torque. After the initial load is applied to
the rope, the clip nuts shall be retightened to the recommended
torque to compensate for any further decrease in rope diameter
during usage.
(f) Swaged or compressed fittings shall be applied as rec-
ommended by the rope, hoist, or fitting manufacturer or a
qualified person.
(g) If a load is supported by more than one part of rope, the
tension on the parts shall be equalized.
(h) Wherever exposed to ambient temperatures at the rope
in excess of 180F (82C), rope having an independent wire-
rope or wire-strand core, or other temperature-damage resis-
tant core, shall be used.
16-1.2.7 Load Sprockets
(a) Load sprockets shall have pockets or teeth to allow
engagement of the load chain.
(b) Load sprockets shall be guarded.
(c) Provision shall be made to guard against jamming of
the load chain within the hoisting mechanism under normal
operating conditions.
16-1.2.8 Load Chain
(a) Load chain may be either roller or welded link type.
Chain shall be pitched (calibrated) so as to pass over all load
sprockets without binding.
(b) Roller load chain shall comply with ASME B29.24.
(c) Welded link type load chain shall be proof tested by the
chain or hoist manufacturer with a load at least equivalent to
1 1/2 times the hoists rated load divided by the number of
chain parts supporting the load.
(d) If a load is supported by more than one part of
load chain, the tension on the parts shall be equalized.
(e) Welded link type load chain properties do not conform
to those shown in ASME B30.9. Roller load chain properties
do not conform to those shown in ASME B29.1M.
2012 CIA, Inc. Illegal to reproduce without written permission.
16-1.2.9 Hooks
If hooks are of the swiveling type, they should rotate freely.
Hooks shall be equipped with latches unless use of the latch
creates a hazardous condition. When required, a latch shall be
provided to bridge the throat opening of the hook and retain,
under slack conditions, such items as, but not limited to, slings
and chains. Refer to ASME B30.10.
16-1.2.10 Load Blocks
(a) Hand Chain-Operated Hoist . Means shall be provided
to guard against load chain jamming in the load block under
normal operating conditions.
(b) Electric- or Air-Powered Hoist. Load blocks shall be
of the enclosed type, and means shall be provided to guard
against rope or load chain jamming in the load block under
normal operating conditions.
16-1.2.11 Brakes
(a) Hand Chain-Operated Hoist. Hand chain-operated
hoist(s) shall be so designed that, when the actuating force is
removed, it will automatically stop and hold any test load up
to 125% of the rated load.
(b) Electric-Powered Hoist
(1) Under normal operating conditions with rated load
and test conditions with test loads up to 125% of rated load,
the bra king system shall perform the following functions:
(a) stop and hold the load hook when controls are
released
(b) limit the speed of load during lowering, with or
without power, to a maximum speed of 120% of rated lower-
ing speed for the load being handled
(c) stop and hold the load hook in the event of a com-
plete power failure
(2) The braking system shall have thermal capacity for
the frequency of operation required by the service.
(3) The braking system shall have provision for
adjustments where necessary to compensate for wear.
(4) Electric-powered hoists that handle molten material
shall be equipped with one of the following arrangements:
(a) Two holding brakes shall be provided, one of which
is applied to a gear reducer shaft, plus control braking means.
Each holding brake shall have a torque rating not less than
100% of rated load hoisting torque at the point where the
brake is applied.
(b) One holding brake shall be provided if the hoisting
unit has a mechanical load brake or a control braking means
that provides controlled lowering of the load upon loss of
power. The holding brake shall have a torque rating not less
than 150% of rated load hoisting torque at the point where
the brake is applied.
(c) Air-Powered Hoist
60
 ASME B30.16 (2007) Overhead Hoists (Underhung)
(1) Under normal operating conditions with rated load
and test conditions with test loads up to 125% of rated load,
the braking system shall perform the following functions:
(a) stop and hold the load hook when controls are
released
(b) prevent an uncontrolled lowering of the load in the
event of a loss of air pressure
(2) The braking system shall have thermal capacity for
the frequency of operation required by the service.
(3) The braking system shall have provision for adjust-
ments where necessary to compensate for wear.
16-1.2.12 Hand Chain (Hand Chain-Operated
Hoists Only)
(a) The hand chain shall be of a shape and pitch to fit the
hand chain wheel without binding or jamming under normal
operating conditions.
(b) The hand chain shall be guarded to prevent disengage-
ment from the hand chain wheel.
(c) The hand chain shall withstand, without permanent
distortion, a force of three times the pull required to lift the
rated load.
(d) Hand chain properties do not conform to those shown
in ASME B30.9.
16-1.2.13 Overtravel Restraint (Hand Chain Oper-
ated Hoists Only)
Before the load chain can be completely run out of the hoist,
it shall be restrained in its fully extended position. The restraint
shall be such that the unloaded hoist can withstand a lowering
hand chain force equivalent to twice the pull required to lift
the rated load or, with rated load on the hoist, a hand chain
force equivalent to the pull required to lift the rated load.
16-1.2.14 Overtravel Protection (Electric- or Air-
Powered Hoists Only)
The hoist shall be so designed and constructed that the load
hook, either loaded or empty, shall not exceed the upper limit
of travel. On wire-rope hoists, if a geared or other lift-limiting
device that operates in relation to drum turns is used, an ad-
ditional lift-limiting device that operates independently of
drum rotations shall be provided.
16-1.2.15 Power Failure Protection (Electric- or
Air-Powered Hoists Only)
Partial or complete interruption of the power supply (air or
electric) during operation shall not result in uncontrollable
motion of the load.
16-1.2.16 Lubrication
If lubrication is required, accessible means for lubrication
should be provided.
61
16-1.2.17 Manual
The manufacturer shall furnish an instruction manual with
each hoist. The manual shall include information on the fol-
lowing:
(a) installation
(b) operation
(c) inspection and testing
(d) lubrication, maintenance, and repair
(e) wiring diagram (electric powered only; may be supplied
separately)
Section 16-1.3 -- Installation
16-1.3.1 Procedure
(a) Procedures for installation recommended in the manual
should be followed.
(b) When a hoist is suspended from a trolley, a trolley and
monorail, or a trolley and crane, and the rated load of each
of these pieces of equipment is different, the rated load for
the system utilizing this combination of equipment shall be
based on the lowest minimum rated load of any individual
piece of equipment or structure within the system.
16-1.3.2 Support
The supporting structure, including trolleys, monorail, or
crane, shall be designed to withstand the loads and forces
imposed by the hoist for the rated load.
16-1.3.3 Location
(a) Hoists shall be installed in locations that will allow
movement of the operator to stay clear of the load.
(b) When hoists are used in hazardous locations as defined
by ANSI/1\TFPA 70, modifications to these rules or additional
safety requirements may be necessary.
(c) When hoists are used to handle molten material, modi-
fications to these rules or additional safety requirements may
be necessary. Refer to ANSI Z241.2.
(d) When electric hoists are used in locations other than
general indoor applications, control enclosures should be
selected in accordance with ANSl / NEMA No. lCS6.
(e) Pendant controls of electric- or air-powered hoists should
be located at a convenient level above the operating floor.
(f) An electric- or air-powered hoist shall not be installed
where the load hook can be lowered beyond the rated hook
travel under normal operating conditions unless the hoist is
equipped with a lower limit device.
(g) Where the slack load chain hanging from the hoist may
create a hazard to operations or personnel, a chain container
recommended by the hoist manufacturer or qualified person
should be used.
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 ASME B30.16 (2007) Overhead Hoists (Underhung)
(h) When hoists are supported and used on cranes, trolleys,
or monorails, modifications to these rules or additional safety
requirements may be necessary. Refer to ASME B30.11 and
ASME B30.17.
16-1.3.4 Power Connections
(a) Electric-powered hoists shall be connected in accordance
with ANSI/NFPA 70.
(b) Air-powered hoists shall be connected to an air supply
not exceeding the rated pressure at the hoist under normal
operating conditions. To prevent excessive brake wear or
heating, the air supply should be sufficient to operate the brake
release mechanism, if provided.
16-1.3.5 Direction of Motion (Electric- or Air-Pow-
ered Hoists Only)
(a) Electric-Powered Hoists. Polyphase hoist motors shall
be connected to the power supply lines in such a manner that
the hook motion agrees with the control marking. Internal
connections in the hoist or pendant station wiring shall not be
changed to accomplish this. Phase reversal (motor reversal),
if necessary, shall be accomplished by reversing the power
leads to the hoist unit.
(b) Air-Powered Hoists. Air hoist motors shall be connected
in such a manner that the hook motion agrees with the control
marking.
16-1.3.6 Check Points
After installation, a check should be made as indicated in
para. 16-2.1.2.
Chapter 16-2
Inspection, Testing, and Maintenance
Section 16-2.1: Inspection
16-2.1.1 Inspection Classification
(a) Initial Inspection. Prior to initial use, all new, altered,
or modified hoists shall be inspected by a designated person
to verify compliance with the applicable provisions of this
volume.
(b) Inspection procedures for hoists in regular service are
divided into two general classifications based upon the inter-
vals at which inspection should be performed. The intervals in
turn are dependent upon the nature of the critical components
of the hoist and the degree of their exposure to wear, deterio-
ration, or malfunction. The two general classifications are
herein designated as frequent and periodic, with respective
intervals between inspections as defined below:
(1) Frequent Inspection. Visual examinations by the
operator or other designated person with records not required.
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62
(a) normal service monthly;
(b) heavy service weekly to monthly;
(c) severe service daily to weekly;
(2) Periodic Inspection. Visual inspection by a designated
person who makes records of external conditions to provide
the basis for a continuing evaluation. An external coded mark
on the hoist is an acceptable identification in lieu of records.
(a) normal service yearly
(b) heavy service semiannually;
(c) severe service quarterly;
16-2.1.2 Frequent Inspection
(a) Frequent inspections shall be performed at intervals
defined in para. 16-2.1.1(b)(1) and shall include observations
during operation.
(b) A designated person shall determine whether conditions
found during the inspection constitute a hazard and whether
a more detailed inspection is required.
(c) The following items shall be inspected:
(1) operating mechanisms for proper operation, proper
adjustment, and unusual sounds;
(2) hoist upper limit device of electric- or air-powered
hoists, without a load on the hook at the beginning of each
shift. Care shall be exercised. The load block shall be inched
into its limit device or run in at slow speed on multi-speed or
variable-speed hoists.
(3) hoist braking system for proper operation;
(4) lines, valves, and other parts of air systems for leakage;
(5) hooks in accordance with ASME B30.10, Frequent
Inspection;
(6) hook latches, if used,, for proper operation;
(7) hoist rope on accordance with para. 16-2.4.1(a) [or
see 2-2.4.1];
(8) hoist load chain in accordance with para. 16-2.5.1 or
16.2.6.1;
(9) rope or load chain reeving for compliance with recom-
mendations of the hoist manufacturer.
16-2.1.3 Periodic Inspection
(a) Periodic inspections shall be performed at intervals
defined in para. 16-2.1.1(b)(2) and may be performed with
the hoist at its normal location and do not require the hoist to
be disassembled.
(b) Covers and other items normally supplied to allow
inspection of components should be opened or removed.
(c) A designated person shall determine whether conditions
found during inspection constitute a hazard and whether disas-
sembly is required.
(d) The following items shall be inspected:
(1) the items listed in 16-2.1.2(c);
(2) fasteners for evidence of loosening;
(3) load blocks, suspension housings, hand chain wheels,
 ASME B30.16 (2007) Overhead Hoists (Underhung)
chain attachments, clevises, yokes, suspension bolts, shafts,
gears, bearings, pins, rollers, and locking and clamping de-
vices for evidence of wear, corrosion, cracks, and distortion;
(4) hook retaining nuts or collars, and pins, welds, or
rivets used to secure the retaining members for evidence of
damage;
(5) load sprockets, idler sprockets, drums, and sheaves
for evidence of damage and wear;
(6) the brake mechanism on hand chain hoists for evidence
of worn, glazed, or oil-contaminated friction disks; worn pawls,
cams, or ratchets; corroded, stretched, or broken pawl springs;
(7) the motor brake and load brake on electric- or air-
powered hoists for evidence of wear;
(8) electrical apparatus on electric-powered hoists for
evidence of pitting or deterioration of controller contacts;
(9) supporting structure of trolley, if used, for evidence
of damage;
(10) label or labels required by para. 16-1.1.4 for leg-
ibility;
(11) end connections of wire ropes or load chains for evi-
dence of wear, corrosion, cracks, damage, and distortion;
(12) hoist rope shall be inspected in accordance with para.
16-2.4.1(b);
(13) function labels on pendant control stations on elec-
tric- and air-powered hoists for legibility;
(14) the hoist and hoist mounting for evidence of missing
items.
16-2.1.4 Hoists Not in Regular Service
(a) A hoist that is used infrequently, which has been idle for
a period of one month or more, but less than one year, shall be
inspected, before being placed in service, in accordance with
the requirements listed in para. 16-2.1.2.
(b) A hoist that is used infrequently, which has been idle
for a period of one year or more, shall be inspected, before
being placed in service, in accordance with the requirements
listed in para. 16-2.1.3.
16-2.1.5 Inspection Records
(a) Dated inspection reports and records should be main-
tained at time intervals specified in para. 16-2.1.1(b)(2). Re-
cords should be stored where they are available to appointed
persons.
(b) A long-range rope or chain inspection program should
be established and should include records on examination of
ropes or chains removed from service so a relationship can be
established between visual observation and actual condition
of the rope or chain.
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Section 16-2.2: Testing
16-2.2.1 Operational Tests
New hoists shall be tested by the hoist manufacturer to
ensure compliance with this volume as specified in para. 16-
2.2.1(a) or 16-2.2.1(b). Altered or repaired hoists, or hoists that
have not been used within the preceding 12 months, shall be
tested by a designated person prior to the hoist being placed
in service to verify compliance with this volume as specified
in para. 16-2.2.1(a) or 16-2.2.1(b).
(a) Hand Chain Operated Hoists
(1) Lifting and lowering functions shall be tested under
no-load conditions (testing through complete rated lift length
is not required).
(2) After testing under no-load conditions, a load of at
least 50 lb (23 kg) times the number of load supporting parts
of chain shall be applied to the hoist, and the hoist shall be
tested to check proper load control.
(b) Electric- or Air-Powered Hoists
(1) Lifting and lowering functions shall be tested under
no-load conditions (testing through complete rated lift length
is not required).
(2) Operation of brake(s) shall be tested under no-load
conditions.
(3) Trip-setting of limit devices shall be determined by
tests under no-load conditions. Tests shall be conducted first
by hand, if practical, and then under slowest speed obtainable.
Test with increasing speeds up to maximum speed. Actuat-
ing mechanisms shall be located so that they will trip the
switches or limiting devices in sufficient time to stop motion
without damage to any part of the hoisting arrangement. On
hoists having adjustable trip-setting limit devices, care shall
be exercised to achieve adjustment setting without the load
block striking the hoist frame or without all the slack being
taken out of the unloaded chain or less than one wrap of rope
on the drum.
16-2.2.2 Load Test
(a) Hand Chain Operated Hoists
(1) New hoists shall be tested by the manufacturer as
specified in para. 16-2.2.1(a)(1) with a test load of not less
than 125% of the rated load, except that if load testing of
the hoist cannot be performed by the manufacturer, the user
shall be notified and the load test shall be accomplished at
another location or job site, by or under the direction of a
designated person prior to the hoist being placed in service.
(2) Hoists in which load-suspension parts have been al-
tered, replaced, or repaired shall be statically or dynamically
load tested as determined by a qualified person. If a qualified
person determines that a load test is required, the load test
shall be performed.
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 ASME B30.16 (2007) Overhead Hoists (Underhung)
(a) If a load test is conducted, the load test shall be
conducted by or under the direction of a designated person as
specified below. Lifting and lowering functions shall be tested.
(Testing through complete rated lift length is not required.)
(b) If the load test is conducted, the test load shall not
be less than 100% of the rated load of the hoist or more than
125% of the rated load of the hoist unless otherwise recom-
mended by the hoist manufacturer or a qualified person.
(c) If a load test is conducted, the person conducting the
load test shall prepare a written report of the load sustained
during the test and the operations performed during the test.
Reports shall be placed on file.
(d) The replacement of load chain is specifically ex-
cluded from this load test; however, an operational test of the
hoist should be made in accordance with para. 16-2.2.1(a)(2)
prior to putting the hoist back in service.
(b) Electric- or Air-Powered Hoists
(1) Complete new hoists shall be dynamically load tested
by the manufacturer as specified in paras. 16-2.2.1(b)(1) and
(2) with a test load of not less than 125% of the rated load,
except that if testing of the hoist cannot be performed by the
manufacturer, the user shall be notified and the load test shall
be accomplished at another location or job site, by or under
the direction of a designated person prior to the hoist being
placed in service.
(2) Hoists in which load-suspension parts have been al-
tered, replaced, or repaired should be statically or dynamically
load tested as determined by a qualified person.
(a) If a load test is conducted, the load test shall be
conducted by or under the direction of a designated person
as specified below.
(1) Lifting and lowering functions shall be tested.
(Testing through complete rated lift length is not required.)
(2) Operation of brake(s) shall be tested.
(b) If a load test is conducted, the test load shall not
be less than 100% of the rated load of the hoist or more than
125% of the rated load of the hoist unless otherwise recom-
mended by the hoist manufacturer or a qualified person.
(c) If a load test is conducted, the person conducting the
load test shall prepare a written report of the load sustained
during the test and the operations performed during the test.
Reports shall be placed on file.
(d) The replacement of load chain or rope is specifi-
cally excluded from this load test; however, an operational
test of the hoist should be made in accordance with para. 16-
2.2.2(b)(1) and (2) prior to putting the hoist back in service.
(e) Test anchorages or suspensions shall be approved
by a qualified person.
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64
Section 16-2.3: Maintenance
16-2.3.1 Preventive Maintenance
(a) A preventive maintenance program should be estab-
lished. The program should be based on recommendations
outlined in the hoist manufacturers manual. If a qualified
person determines it is appropriate, the program should also
include that individuals additional recommendations based
upon a review of the hoist application and operation. Dated
records should be placed on file.
(b) Replacement parts shall be at least equal to the original
manufacturers specifications.
16-2.3.2 Maintenance Procedure (Refer to Hoist
Manufacturers Manual)
(a) Before adjustments and repairs are started on a hoist,
the following precautions shall be taken as applicable:
(1) If a load is attached to the hoist, it shall be removed.
(2) If the hoist is electric- or air-powered, all controllers
shall be placed in the off position.
(3) If the hoist is electric- or air-powered, a lockout/tagout
procedure shall be performed (see Section 16-3.3).
(4) If the hoist is suspended from a trolley, provisions
should be taken to prevent movement of the trolley.
(5) Warning signs and barriers shall be utilized on
the floor beneath the hoist where overhead maintenance work
creates a hazard.
(b) After adjustments and repairs have been completed and
before restoring the hoist to normal operation
(1) guards shall be reinstalled
(2) safety devices shall be reactivated
(3) parts that have been replaced and loose material shall
be removed
(4) maintenance equipment shall be removed, and
(5) warning signs and barriers, when used, shall be
removed
(c) Warning signs and barriers, when used, shill be placed
and removed only by designated persons.
16-2.3.3 Adjustments, Repairs, and Replacements
(a) Any condition disclosed by the inspections performed
in accordance with the requirements of Section 16-2.1, that
is determined to be a hazard to continued operation, shall be
corrected by adjustment, repair, or replacement before con-
tinuing the use of the hoist.
(b) Adjustments, repairs, and replacements shall be
performed by a designated person.
(c) Components shall be adjusted or repaired as needed.
The following are examples:
(1) all operating mechanisms
(2) brakes and pawls
(3) limit devices of electric- or air-powered hoists
(4) control systems of electric- or air-powered hoists
 ASME B30.16 (2007) Overhead Hoists (Underhung)
(d) Repairs or replacements shall be made as needed. The
following are examples:
(1) all excessively worn braking components such as
friction disks, ratchets, pawls, and pawl springs.
(2) all critical parts, including load suspension compo-
nents, that are cracked, broken, bent, or excessively worn.
(3) worn, corroded, or .otherwise damaged load chain
in accordance with para. 16-2.5.2 or 16-2.6.2.
(4) worn or otherwise damaged rope in accordance with
para. 16-2.4.2.
(5) damaged or worn hooks as described under Mainte-
nance in ASME B30.10. Repairs by welding or reshaping are
not recommended.
(6) on electric-powered hoists, pitted or burned electrical
contacts should be corrected only by replacement and in sets.
Controller parts should be lubricated as recommended by the
manufacturer.
(7) missing or illegible function labels on pendant control
stations.
(8) missing or illegible warning labels.
(9) items that are determined to be missing.
16-2.3.4 Lubrication
(a) All moving parts of the hoist for which lubrication is
specified should be regularly lubricated. Lubricating method
should be checked for delivery of lubricant. Care should be
taken to follow recommendations outlined in the hoist man-
ufacturers manual as to points and frequency of lubrication,
and quantity and types of lubricant to be used.
(b) Hoist machinery shall be stationary while lubricants
are being applied except when lubricating load chain or rope
unless equipped for automatic or remote lubrication.
Section 16-2.4: Rope Inspection, Replacement,
and Maintenance
16-2.4.1 Rope Inspection
(a) Frequent Inspection
(1) The operator or other designated person should visu-
ally inspect all ropes at the start of each shift. These visual
observations should be concerned with discovering gross
damage, such as listed below, which may be an immediate
hazard:
(a) distortion of the rope such as kinking, crushing,
unstranding, birdcaging, main strand displacement, or core
protrusion.
(b) general corrosion.
(c) broken or cut strands.
(d) number, distribution, and type of visible broken
wires. [See paras. 16-2.4.2(b )(1), (2), and (3) for further
guidance.]
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(2) When such damage is discovered, the rope shall either
be removed from service or given an inspection as detailed
in para. 16-2.4.1(b).
(b) Periodic Inspection
(1) The inspection frequency shall be determined by a
qualified person and shall be based on such factors as ex-
pected rope life as determined by experience on the particular
installation or similar installations; severity of environment;
percentage of capacity lifts; frequency rates of operation; and
exposure to shock loads. Inspections need not be at equal
calendar intervals and should be more frequent as the rope
approaches the end of its useful life.
(2) Periodic inspections shall be performed by a desig-
nated person. This inspection shall cover the entire length of
rope. The individual outer wires in the strands of the rope shall
be visible to this person during the inspection. Any deteriora-
tion resulting in appreciable loss of original strength, such as
described below, shall be noted, and determination shall be
made as to whether further use of the rope would constitute
a hazard:
(a) points listed in para. 16-2.4.1(a)
(b) reduction of rope diameter below nominal diam-
eter due to loss of core support, internal or external corrosion,
or wear of outside wires
(c) severely corroded or broken wires at end connections
(d) severely corroded, cracked, bent, worn, or im-
properly applied end connections
(3) Special care should be taken when inspecting sec-
tions of rapid deterioration, such as the following:
(a) sections in contact with saddles, equalizer sheaves,
or other sheaves where rope travel is limited
(b) sections of the rope at or near terminal ends where
corroded or broken wires may protrude
(c) sections subject to reverse bends
(d) sections of rope that are normally hidden during
visual inspection, such as parts passing over sheaves
16-2.4.2 Rope Replacement
(a) No precise rules can be given for determination of the
exact time for rope replacement, since many variable factors
are involved. Once a rope reaches any one of the specified
removal criteria, it may be allowed to operate to the end of
the work shift, based on the judgment of a qualified person.
The rope shall be replaced after that work shift, at the end of
the day, or at the latest time prior to the equipment being used
by the next work shift.
(b) Removal criteria for the rope replacement shall be as
follows:
(1) in running ropes, twelve randomly distributed broken
wires in one rope lay or four broken wires in one strand in
one rope lay, except as noted in para. 16-2.4.2(b )(2)
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 ASME B30.16 (2007) Overhead Hoists (Underhung)
(2) in rotation-resistant ropes, two randomly distributed
broken wires in six rope diameters or four randomly distrib-
uted broken wires in thirty rope diameters
(3) one outer wire broken at the contact point with the
core of the rope, which has worked its way out of the rope
structure and protrudes or loops out from the rope structure
(4) wear of one-third the original diameter of outside
individual wires
(5) kinking, crushing, birdcaging, or any other damage
resulting in distortion of the rope structure
(6) evidence of heat damage from any cause
(7) reductions from nominal diameter greater than those
shown below
Maximum Allowable
Reduction From
Rope Diameter, Nominal Diameter,
in. (mm) in. (mm)
Up to 5/16 (8) 1/64 (0.4)
Over 5/16 to 1/2 (13) 1/32 (0.8)
Over 1/2 to 3/4 (19) 3/64 (1.2)
Over 3/4 to 1-1/8 (29) 1/16 (1.6)
Over 1-1/8 to 1-1/2 (38) 3/32 (2.4)
(c) Broken wire removal criteria, in this volume, applies to
wire ropes operating on steel sheaves and drums. The user shall
contact the sheave, drum or hoist manufacturer, or qualified
person, for broken wire removal criteria for wire ropes operat-
ing on sheaves and drums made of material other than steel.
(d) Attention shall be given to end connections. Upon
development of two broken wires adjacent to a socketed
end connection, the rope should be resocketed or replaced.
Resocketing shall not be attempted if the resulting rope length
will be insufficient for proper operation.
(e) Replacement rope and connections shall have a strength
rating at least as great as the original rope and connections
furnished by the hoist manufacturer. Any deviation from the
original size, grade, or construction shall be specified by a rope
manufacturer, the hoist manufacturer, or a qualified person.
16-2.4.3 Rope Maintenance
(a) Rope should be stored to prevent damage or deterioration.
(b) Rope shall be unreeled or uncoiled in a manner to avoid
kinking of or inducing a twist in the rope.
(c) Before cutting rope, means shall be used to prevent
unlaying of the strands.
(d) During installation, care should be observed to avoid
dragging the rope in dirt or around objects that will scrape,
nick, crush, or induce sharp bends.
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(e) Rope should be maintained in a well-lubricated condi-
tion. Lubricant applied as part of a maintenance program shall
be compatible with the original lubricant. Lubricant applied
shall be of the type that does not hinder visual inspection.
Those sections of rope that are located over sheaves or oth-
erwise hidden during inspection and maintenance procedures
require special attention when lubricating rope. The object of
rope lubrication is to reduce internal friction and to prevent
corrosion.
Section 16-2.5: Welded Link Chain Inspection,
Replacement, and Maintenance
16-2.5.1 Welded Link Chain Inspection
(a) Test the hoist under load in lifting and lowering direc-
tions and observe the operation of the chain and sprockets. The
chain should feed smoothly into and away from the sprockets.
(b) If the chain binds, jumps, or is noisy, first see that it is
clean and properly lubricated. If the trouble persists, inspect the
chain and mating parts for wear, distortion, or other damage.
(c) Examine visually for gouges, nicks, weld spatter, cor-
rosion, and distorted links. Slacken the chain and move the
adjacent links to one side to inspect for wear at the contact
points. If wear is observed or if stretching is suspected, the
chain should be measured as outlined in the hoist manufac-
turers manual. If instructions are not available, proceed as
follows:
(1) select an unworn, unstretched length of the chain (e.g.,
at the slack end);
(2) suspend the chain vertically under tension and, using
a caliper-type gauge, measure the outside length of any con-
venient number of links approximately 12 inches (305 mm)
to 24 inches (610 mm) overall;
(3) measure the same number of links in the used sections
and calculate the percentage increase in length.
16-2.5.2 Welded Link Chain Replacement
(a) If the used chain exceeds the hoist manufacturers recom-
mended length (or in the absence of such recommendation, if
the used chain for hand chain operated hoists is 2 1/2% longer
than the unused chain, or the used chain for powered hoists
is 1 1/2% longer than the unused chain), replace the chain.
Repairing of load chain by welding or any other means shall
not be attempted by anyone other than the chain manufacturer.
(b) The existence of gouges, nicks, corrosion, weld spatter,
or distorted links is sufficient reason to question chain safety
and consider chain replacement. Safety in this respect depends
largely upon the use of good judgement by a designated person
in evaluating the degree of deficiency.
 ASME B30.16 (2007) Overhead Hoists (Underhung)
(c) Replacement chain shall be the same size, grade, and
construction as the original chain furnished by the hoist
manufacturer, unless otherwise recommended by the hoist
manufacturer or a qualified person due to actual working
conditions.
(d) Load chain links which pass over the hoist load sprocket
on edge (alternate to those which lie flat in the pockets) shall
be installed (if recommended by the hoist manufacturer) with
the welds away from the center of the sprocket. This precau-
tion is not required on idler sprockets that change the direction
but not the tension in the chain.
(e) The chain shall be installed without any twist between
the hoist and an anchored end on either the loaded side or
slack side.
(f) When chain is replaced, disassemble and inspect the
mating parts (sprockets, guides, stripper) for wear and replace
if necessary.
(g) Discarded load chain shall not be used for slings.
16-2.5.3 Welded Link Chain Maintenance
(a) Load chain and hand chain should be kept clean and
free from any coating or deposit that will build up and change
their dimensions or reduce flexibility. The cleaning process
shall not damage these chains, and any solution used in the
cleaning process shall be acid-free.
(b) Load chain articulates slowly under high bearing
pressures and should be lubricated as specified by the hoist
manufacturer. Hand chains are lightly loaded and normally
need no lubrication.
Section 16-2.6: Roller Chain Inspection,
Replacement, and Maintenance
16-2.6.1 Roller Chain Inspection
(a) Test the hoist under load in lifting and lowering direc-
tions and observe the operation of the chain and sprockets. The
chain should feed smoothly into and away from the sprockets.
(b) If the chain binds, jumps, or is noisy, first see that it is
clean and properly lubricated. If the trouble persists, inspect
the chain in accordance with (c) and (d) below, and inspect
mating parts for wear, distortion, or other damage.
(c) Roller chain should first be inspected while it is in the
hoist. With the hoist suspended in normal position, apply a
light load of approximately 50 lb (23 kg).
67
(1) Check chain for elongation as outlined in the hoist
manufacturers manual. In the absence of specific instruc-
tions, the chain can be checked by determining the nominal
pitch and measuring a 12-inch (305 mm) section of chain that
normally travels over the chain sprocket. Using a caliper-type
gauge, check the dimension from the edge of one chain pin
to the corresponding edge of another pin for the number of
pitches per foot. If elongation exceeds 1/4 inch (6.3 mm) in 12
inches (305 mm), the chain shall be replaced. For example, a
3/4 inch (19 mm) pitch chain should measure 12 inches (305
mm) over 16 pitches. Chain shall be rejected if measurement
over 16 pitches exceeds 12 1/4 inches (311 mm).
(2) Check chain for twist. The chain shall be replaced if
the twist in any 5-foot (1.52 m) section exceeds 15 degrees.
(3) Check for side bow in plane perpendicular to plane
of roller. A chain which has a side bow exceeding 1/4 inch
(6.3 mm) in any 5-foot (1.52 m) section shall be replaced.
(d) Additional inspection of the chain should be made by
removing chain from hoist and cleaning it thoroughly in an
acid-free solvent. A check should then be made for any of the
following deficiencies:
(1) pins turned from their original position;
(2) rollers that do not run freely with light finger pressure;
(3) joints that cannot be flexed by easy hand pressure;
(4) side plates that are spread open (a visual check of the
pin head extension at the damaged area, as compared to the
pin extension at the free end of the chain, can determine the
amount of spread and the condition of the chain);
(5) corrosion, pitting, or discoloration of chain (generally
indicative of serious impairment);
(6) gouges, nicks, or weld spatter.
16-2.6.2 Roller Chain Replacement
(a) Roller chain shall be replaced if any of the conditions
exist as stated in para. 16-2.6.1(c). Repairing of roller chain
by welding or heating shall not be attempted.
(b) The existence of any of the conditions stated in para. 16-
2.6.1(d) is reason to question chain safety and for a designated
person to give consideration for replacement. Roller chains
are subject to hidden wear and deterioration which must be
considered.
(c) Replacement chain shall be the same size, grade, and
construction as the original chain furnished by the hoist manu-
facturer unless otherwise recommended by the hoist manu-
facturer or qualified person due to actual working conditions.
(d) When chain is replaced, disassemble and inspect the
mating parts (sprockets, guides, stripper) for wear and replace
if necessary.
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 ASME B30.16 (2007) Overhead Hoists (Underhung)
(e) When chain is replaced, it should be reeved as outlined
in the hoist manufacturers manual and should operate freely
over all load and idler sprockets. All connecting links and
chain end fastenings should be inspected and properly secured.
The selection and installation of connecting links should be as
outlined in the hoist manufacturers manual or as determined
by a qualified person.
(f) Discarded roller chains shall not be used for slings.

16-2.6.3 Roller Chain Maintenance

(a) Roller chains should be kept clean and free from rust.
Excessively dirty chains should be soaked in a clean, acid-free
solvent. Chains should be agitated to ensure that all joints are
free from grit and foreign matter.
(b) Roller chains should be lubricated as outlined in the
hoist manufacturers manual. In absence of specific lubrica-
tion instructions, the chains should be lubricated with a good
grade of automotive motor oil SAE grades 20 or 30. Never
apply grease to the chain.

2012 CIA, Inc. Illegal to reproduce without written permission.

68