Pre-Operational Inspection Checklist for Gantry Crane Operators

Pre-operational inspections are critical to ensure the safe operation of gantry cranes. These inspections help identify potential issues before they become serious problems or cause accidents. As a gantry crane operator, you have a legal responsibility under the Health and Safety at Work Act 2015 to ensure that equipment is safe to use. This article outlines a comprehensive pre-operational inspection checklist for gantry crane operators, based on New Zealand standards and regulatory requirements.

Documentation Review

Before operating a gantry crane, check that the crane has a current certificate of inspection, which should be issued by an equipment inspector and renewed annually.

Ensure the crane’s load chart or rating sheet is clearly visible and legible (note that on some cranes, it’s actually on the trolley and therefore not readily visible without using a scissor lift, and therefore it’s a good idea to take a photo of it, print it, laminate it, and keep it in a visible place).

Verify that the crane has a unique identifier permanently marked on it. Review the maintenance logbook to confirm the crane has been properly maintained and that any previous issues have been addressed.

Personal Fitness Assessment

Before operating a gantry crane, assess your own fitness for duty. If you are tired, injured, ill, or under the influence of drugs or alcohol, your judgement and reaction times may be impaired, increasing the risk of accidents. In such cases, inform your supervisor and do not operate the crane until you are fit to do so.

Structural Components Inspection

Conduct a thorough visual inspection of the crane’s structural components. Check the bridge beam, legs, and end carriages for any signs of damage, deformation, or excessive wear. For semi-gantry cranes, pay particular attention to the connection point between the bridge beam and the supporting structure. Look for any cracks, especially in welded areas, and check for loose or missing bolts. Examine the structure for signs of oil leakage, which could indicate hydraulic system problems.

Rails and Wheels Examination

Inspect the rails for signs of wear, misalignment, or obstruction. Check the wheels for flat spots, cracks, excessive wear, or issues with the brakes. Ensure that rail clamps and stops are in place and in good condition. For mobile gantry cranes, verify that the wheels track properly and show no signs of excessive wear or damage.

Hoisting Mechanism Assessment

Examine the hoist rope or chain for signs of wear, kinks, or damage. According to the Approved Code of Practice for Load-Lifting Rigging, wire ropes should be inspected for broken wires, strand distortion, kinks, excessive wear, bird caging, crushing, rust, and stretching. Inspect the hook for deformation, cracks, or excessive wear. Ensure the hook’s safety latch is present and functioning correctly. Check sheaves and drums for signs of wear or damage, and verify that the hook can freely swivel.

Electrical Components Check

Inspect all visible wiring for signs of damage or wear. Verify that all electrical enclosures are properly closed and secured. Ensure that the isolator switch is accessible and functioning. Check electrical controls and connections for signs of burns, loose connections, or corrosion. Confirm that any emergency stop buttons are clearly marked and accessible.

Control Systems Verification

Check that all controls are clearly marked and in good condition. For pendant controls, ensure the support cable is in good condition and that the pendant is properly suspended. For radio controls, verify that batteries are charged and the system is functioning correctly. If you are unfamiliar with the crane, take time to identify the function of each control button before operation.

Operational Checks Without Load

After completing the visual inspection, perform operational checks without a load. Follow the startup procedures provided by the crane manufacturer or installer. Test all motion controls (bridge travel, trolley travel, and hoist) to ensure smooth operation. Verify that all controls return to the neutral position when released. Listen for any unusual vibration or sound during crane movement. Test the emergency stop button to confirm it functions correctly.

Limit Switches and Safety Devices Testing

Check all limit switches, including those for bridge travel, trolley travel, and hoist upper and lower limits. Ensure these switches stop the crane’s motion before reaching the end of travel. Test any anti-collision devices that prevent the crane from colliding with other cranes on the same runway or with fixed obstacles. Verify that overload protection systems are functioning correctly if equipped.

Brake System Assessment

Test the hoist brake to ensure it holds the hook in position when the control is released. Check the bridge and trolley brakes for proper operation. Verify that brakes engage smoothly and do not cause abrupt stops that could induce load swing. Confirm that brakes can hold the crane stationary when controls are in the neutral position.

Warning Devices Confirmation

Check that all warning devices are functioning properly. This includes audible warnings, travel lights, or other indicators that alert workers to crane movements. Verify that any load moment indicators or rated capacity indicators are functioning correctly. If the crane is equipped with an anemometer for wind speed monitoring, ensure it is operational.

Surrounding Area Inspection

Inspect the area around the crane to ensure safe operation. Verify that the operating area is clear of obstacles and personnel. Check for potential interference with other cranes or equipment. Confirm there are no overhead obstructions, particularly electrical lines. For semi-gantry cranes, pay extra attention to the interface between the crane and the supporting structure, checking for signs of stress or misalignment at this connection point.

Documentation of Inspection

After completing all checks, document the inspection in the crane’s logbook or inspection checklist. Record the date, time, and your name as the inspector. Note any issues found and actions taken to address them. If you identified any defects that could affect the safe operation of the crane, report them immediately to your supervisor and ensure the crane is not used until the issues are resolved.

Regular pre-operational inspections are a critical component of safe gantry crane operation. By thoroughly checking the crane before use, operators can identify potential issues before they lead to accidents or equipment failures. Remember that if any defect is found during the inspection that could affect the safe operation of the crane, the crane must not be used until the issue has been addressed. Always follow the manufacturer’s guidelines for specific inspection requirements, as they may vary depending on the type and model of the crane.