Crane Safety Inspection Checklist: Pre-Operation Procedures
Crane Safety Operating Procedures are structured into three phases: pre-operation safety inspection, standard safe operating procedures, and safety device maintenance. Before operation, all 15 items on the inspection checklist must be verified individually. During operation, the Ten No-Lift Rules and safe operating procedures must be strictly followed. Safety devices require periodic maintenance and calibration. Proper adherence to these procedures can reduce human-related operational accidents by over 90%.
Key Data: In 2025, 82% of crane accidents nationwide were linked to improper operation, and 71% occurred when pre-operation inspections were skipped, limit switches were faulty, or safety devices were uncalibrated. Consistent daily inspections and adherence to operating procedures can reduce injury and fatality rates by more than 85%. Per TSG Q7015, the user unit must establish safety operating procedures and conduct regular training and assessment.
Pre-Operation Safety Inspection Checklist
In accordance with TSG Q7015 (Rules for Periodic Inspection of Lifting Appliances), the following 15 safety inspections must be completed before each shift. The crane may only be operated after all inspection items pass. Inspection records must be kept on file for future reference.
1. Wire Rope and Lifting Spreader Inspection (5 Items)
① Wire rope visual inspection: Visually inspect the entire wire rope for broken wires, wear, corrosion, kinking, or crushing. The number of broken wires within one lay length must not exceed 10% of the total.
② Wire rope diameter measurement: Measure the diameter using a vernier caliper. If wear or corrosion exceeds 7% of the original diameter, the rope must be replaced immediately.
③ Hook inspection: Visually inspect the hook for cracks, deformation, or wear. Replace the hook if throat opening deformation exceeds 15% of the original dimension. Verify the hook latch is intact and functional.
④ Pulley inspection: Check that pulleys rotate freely and that rope groove wear depth does not exceed 25% of the original depth.
⑤ Drum inspection: The wire rope must be evenly spooled on the drum with at least 3 safety wraps remaining. The rope guard plate must be intact.
2. Brake and Safety Device Inspection (5 Items)
⑥ Hoisting mechanism brake inspection: Brake shoe open/close action must be smooth with no sticking. Brake clearance: 0.5–1.0 mm for drum brakes; 1.0–2.0 mm for disc brakes.
⑦ Crane bridge and trolley brake inspection: All travel mechanism brakes must actuate in synchronization. Brake wheel surfaces must be free of cracks, pitting, and oil contamination.
⑧ Limit switch verification: Manually trigger the travel limit switches for the crane bridge, trolley, and hoist. Each must actuate reliably with a stopping distance of at least 200 mm from the end limit.
⑨ Overload limiter check: With no load applied, the overload limiter display must read zero and the function indicator light must be normal.
⑩ Audible and visual alarm device: Test the crane bridge and trolley travel alarms before operation. Both audible and visual signals must be clear and functional.
3. Crane Rail and Environment Inspection (5 Items)
⑪ Crane rail surface inspection: Crane rails for both the bridge and trolley must be free of oil, obstructions, and foreign objects. Rail joints must be level and smooth.
⑫ Buffer and anti-collision device inspection: End buffers must be intact with no damage. Laser/infrared anti-collision sensor emitting surfaces must be clean.
⑬ Wind protection device inspection (outdoor equipment): Rail clamps and anchor devices must open and close freely. The anemometer must display correctly.
⑭ Operating environment inspection: The operating area must have adequate lighting, be free of improperly stored flammable or explosive materials, and safety passages must be unobstructed.
⑮ No-load test run: Perform one full hoisting cycle through the entire stroke, and one full travel cycle for both the crane bridge and trolley. All mechanisms must operate smoothly with no abnormal noise and proper braking. Kelude recommends recording each no-load test run in the work log as documentation for the daily inspection record.
Standard Safe Operating Procedures
Safe crane operation is divided into four phases: pre-lift preparation, hoisting operation, travel operation, and lowering and unloading. The following procedures must be strictly implemented at each stage.
1. Pre-Lift Preparation
① Confirm the load weight does not exceed the rated lifting capacity (verify by visual estimation or load label; use the load limiter if in doubt).
② Confirm the lifting spreader is properly matched to the load. The included angle between wire rope legs must not exceed 90 degrees (60 degrees or less is recommended; derate the load if the angle is larger).
③ Confirm the center of gravity of the load and select correct lifting points. The load must be securely rigged with no risk of loosening.
④ Confirm no personnel or other equipment are within the load path, and plan a clear lifting and transport route.
⑤ Confirm the hand signal system is functional (hand signals, flag signals, or two-way radio) and that the operator and the crane operator in charge / signal person are in agreement on signals.
2. Hoisting Operation
⑥ Sound the horn or activate the audible and visual alarm before lifting to alert personnel to move to a safe area.
⑦ Use jog mode to lift slightly until the wire rope is taut, then stop. Check that the load is securely rigged and the center of gravity is stable.
⑧ Stop again when the load is approximately 200 mm above the ground. Verify the brake holds reliably (no natural load drift), then continue hoisting.
⑨ Hoist at a steady, uniform speed. Never perform sudden stops or starts. Maintain a minimum safety distance of 500 mm between the bottom of the load and the highest point of any ground obstacle.
3. Travel Operation
⑩ Lifting height during travel: The bottom of the load must clear the highest obstacle along the planned route by at least 500 mm.
⑪ When moving the crane bridge and trolley simultaneously, start the bridge first and then the trolley. When decelerating, stop the trolley first and then the bridge to prevent excessive load swing.
⑫ Travel Speed Control: Use the low-speed setting (50%–70% of rated speed) when carrying a full load; the high-speed setting may be used under no-load conditions. Never operate the hoisting and travel mechanisms at the same time (cross-operation).
⑬ No Personnel Under Suspended Load: No one may stand or pass beneath the load or within the affected area during travel.
4. Lowering and Landing the Load
⑭ Before lowering the hook, confirm that the landing zone is clear of obstructions and personnel. Lower smoothly and switch to creep speed when the load is approximately 300 mm above the landing point.
⑮ Once the load is securely landed, remove the lifting spreader. Only raise the hook after confirming the load is stable and presents no tipping hazard.
⑯ Raise the hook to its highest position (at least 500 mm below the upper limit switch), return all mechanisms to their neutral positions, and switch off the main power supply. After the operation, complete the work log, recording shift performance and any abnormalities.
Ten No-Lift Rules for Crane Safety
The Ten No-Lift Rules are the fundamental safety baseline for crane operation and a core element of TSG inspections and safety audits at all levels. Hoisting is strictly prohibited under the following ten conditions:
1. No Lifting Overload
Never lift loads exceeding the Rated Lifting Capacity or when the load moment limiter alarms. Overloading is the leading cause of structural damage and crane overturning.
2. No Lifting with Unclear Signals
Never operate when hand signals are unclear, multiple people are giving signals simultaneously, or no signal person is present. Confirm that hand signals are unified before lifting.
3. No Lifting with Angled Pull
Never pull a load that is not directly beneath the hook. Angled pulling can cause wire rope derailment, load swing and impact, or overload.
4. No Lifting with People Under the Load
Never lift or travel when personnel are beneath the load or within its travel path. All personnel must move to a safe area.
5. No Lifting with Failed Safety Devices
Never operate if any safety device—limit switch, overload limiter, or brake—is malfunctioning. Repair and verify proper function before resuming operation.
6. No Lifting with Unsafe Rigging
Never use wire rope with excessive wire breaks, hooks with cracks or deformation, or lifting slings with severe wear. All rigging must be in good condition and correctly sized.
7. No Lifting of Buried Loads
Never lift loads that are buried, pinned, or secured to the ground or other objects. Forced lifting can cause wire rope breakage or structural damage.
8. No Lifting with Insecure Rigging
Never lift if the load is not securely rigged, the center of gravity is offset, or the lifting point position creates a tipping hazard. Re-rig and confirm stability before lifting.
9. No Lifting in Severe Weather
Never perform outdoor lifting operations in winds of Force 6 or above (wind speed ≥13.8 m/s), heavy rain, heavy snow, dense fog, or other severe weather conditions.
10. No Lifting Without Certification
Never allow untrained personnel or those without a valid special equipment operator certificate to operate the crane. The operator certificate must be within its validity period.
Common Violations at a Glance: A Side-by-Side Comparison
| Violation of Operating Procedures | Common Scenarios | Immediate Hazards | Accident Consequences | Correct Practices |
|---|---|---|---|---|
| overload Lifting | Visual Estimation Weight, Lifting and transport Overweight Load | structure Overload Stress, Braking Failure | Main Girder Cracking/Collapse/Overturning | Use Overload Limiter Verification Weight |
| Angular Lifting (Out-of-Plumb Pulling) | Off-Center Load, Operator Rushing (Haste) | wire rope derailment, Load Swing | Wire rope breakage/Personnel Strike (Impact) | Re-adjustment Lifting point Directly Below (Positioning) |
| Standing Under Suspended Load | "Brief Moment (Nonchalant Attitude)" | Direct Impact from Falling Load | Casualties (Personnel Injury/Fatality)(Most Severe) | Lifting and transport Full Area Enclosure (Barricading), Erecting Warning Tape/Barricade |
| Limit Switch Bypassing (Safety Device)/Dismantling | limit switch Annoyance with Frequent Operations, Unauthorized Bypassing | stroke Overshoot, Wire Ropeover-hoisting | Two-Block (Load Block Traveling to Headroom)/Derailment/Wire rope breakage | Limit Switch Must Be Intact and Functional, Must Not Be Bypassed |
| Under load High-Speed Operation | Lifting and transport Long Travel Distance, Rushing to Save Time | Uncontrolled Excessive Load Swing | Striking Personnel/Equipment Drop (Fall) | Full load Using Low-Speed Mode(50%~70%) |
| Failure to (Before Operation)inspection | Time Pressure, Perceived as Unnecessary | Undetected Hazards, Operation with Existing Defects (Running with Faults) | Sudden Malfunction/Accident During Operation | Complete Item-by-Item Before Each Shift15Iteminspection |
Safety Device Maintenance Intervals
Safety devices serve as the last line of defense for safe crane operation. Each device must be inspected and maintained at regular intervals to ensure it remains fully functional at all times. The table below outlines the standard maintenance cycles for each safety device:
Lifting Height Limit Switch
Inspection: Weekly manual trigger test
Operating threshold: Reliable trip at ≥200mm from end limit
Calibration: Quarterly verification of trip accuracy
Overload Limiter
Inspection: Daily zero-point check
Operating threshold: Alarm and power cut-off above 105% of rated load
Calibration: Quarterly using standard test weights
Travel Limit Switch
Inspection: Weekly three-direction test (bridge, trolley, hoist)
Operating threshold: Reliable stop at ≥200mm from rail end
Maintenance: Never bypass or remove the limit switch
Buffers & Anti-Collision
Inspection: Monthly visual integrity check
Rubber aging: Replace upon cracking or permanent deformation
Anti-collision sensors: Weekly cleaning of emitter/receiver faces
Wind Protection Device
Inspection: Weekly rail clamp / anchoring open-close operation
Anemometer: Quarterly wind speed accuracy calibration
Alarm threshold: Warning and work stoppage at 13.8m/s (Beaufort 6)
Emergency Stop Device
Inspection: Daily push-button test before operation
Operating threshold: Immediate power cut-off to all drives when pressed
Reset: After twist-release reset, mechanisms must not auto-restart
Frequently Asked Questions (FAQ)
Q: How long does a pre-operation crane inspection take?
A: A complete pre-operation inspection takes approximately 15–20 minutes, including wire rope visual and diameter checks (5 minutes), brake and limit switch testing (5 minutes), crane rail and environment inspection (3 minutes), and a No-Load Test Run (2–3 minutes). Per ISO 4301 Crane Design Standard, Section 9.3, daily inspection records must be signed and kept on file for future reference. Kelude Heavy Industry recommends using a standardized checklist with item-by-item sign-off to ensure full coverage.
Q: What are the Ten No-Lift Rules for crane operation?
A: The Ten No-Lift Rules are 10 prohibitions that govern safe crane operation: ① No lifting overloads; ② No lifting with unclear signals; ③ No side-pulling or angled lifts; ④ No lifting over personnel; ⑤ No lifting with failed safety devices; ⑥ No lifting with unsafe lifting spreaders; ⑦ No lifting buried loads; ⑧ No lifting with insecure rigging; ⑨ No lifting in severe weather; ⑩ No lifting without proper certification. These ten rules are mandatory checkpoints in all safety inspections, and violations are subject to administrative penalties.
Q: How often should crane limit switches be inspected?
A: All three directional limit switches (hoisting, crane bridge, and trolley) must be manually triggered and verified weekly to confirm reliable activation and stopping at a minimum distance of 200 mm from the end limit. Quarterly calibration with standard instruments is required to verify operating accuracy (deviation must not exceed ±5% of the set value). Limit switches must never be bypassed, dismantled, or adjusted beyond the rated stroke. If a limit switch fails, the crane must be shut down immediately for repair, and a No-Load Test Run must confirm normal operation before resuming work.
Q: Which department develops crane safety operating procedures?
A: Under the Special Equipment Safety Law and TSG Q7015 requirements, the safety management department of the user unit is responsible for developing crane safety operating procedures. These procedures must cover inspection checklists, operation workflows, the Ten No-Lift Rules, and safety device maintenance. Procedures must be revised every two years, and all operators must undergo training assessment after each revision. The operating procedures must be posted in a visible location inside the operator's cab or near the equipment.
