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Crane Assembly Checklist

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Crane Assembly Safety Checklist

This checklist is designed to ensure the safe assembly of cranes. It covers key areas of inspection and procedures to follow during the assembly process. Completion of this checklist is required before crane operation.

I. Pre-Assembly Inspection

A. Site and Ground Conditions

[ ] Site is adequate for safe assembly operations [1]
[ ] Ground conditions are adequate to support the equipment during assembly [1]
[ ] Ground is level within 1% grade [2]

B. Blocking Material [1]

[ ] Size and amount of blocking are sufficient to sustain loads
[ ] Blocking is in good condition
[ ] Method of stacking the blocking maintains stability
[ ] Blocking is appropriately placed to protect the structural integrity of the equipment [1]
[ ] Blocking prevents dangerous movement and collapse [1]

C. Component Inspection [3]

[ ] Each crane component inspected by a qualified person for damage or excessive wear [3]
[ ] Components that will be difficult to inspect thoroughly during shift inspections receive particular attention [3]
[ ] Damaged or worn components are not erected unless repaired and reinspected [3]
[ ] Components needing monitoring are documented for monthly inspections [3]

II. During Assembly

A. Assist Crane (if applicable) [1]

[ ] Loads imposed on the assist crane at each phase of assembly are verified before assembly begins [1]

B. Boom and Jib Pick Points [1]

[ ] Rigging attachment points on the boom/jib are suitable for preventing structural damage [1]
[ ] Rigging attachment points facilitate safe handling of components [1]

C. Center of Gravity [1]

[ ] Center of gravity of the load is identified if necessary for maintaining stability [1]
[ ] Measures are in place to prevent unintended dangerous movement resulting from inaccurate identification of the center of gravity [1]

D. Stability [1]

[ ] Boom sections, suspension systems, and components are rigged or supported to maintain stability upon pin removal [1]
[ ] Suspension ropes and pendants are not allowed to catch on boom or jib connection pins or cotter pins [1]
[ ] Potential for unintended movement from inadequately supported counterweights is addressed [1]

E. Wire Rope [4]

[ ] Replacement rope is the same size, grade, and construction as the original rope [4]
[ ] If a load is supported by more than one part of rope, the tension in the parts is equalized [4]

III. Post-Assembly Inspection and Testing

A. General Inspection [2]

[ ] All new and altered cranes are inspected prior to initial use to ensure compliance with standards [2]
[ ] Functional operating mechanisms are checked for maladjustment interfering with proper operation [4]
[ ] Deterioration or leakage in lines, tanks, valves, drain pumps, and other parts of air or hydraulic systems are checked [4]
[ ] Hooks are inspected for deformation or cracks [4]
[ ] Hoist or load attachment chains, including end connections, are checked for excessive wear, twist, distorted links interfering with proper function, or stretch beyond manufacturer's recommendations [5]
[ ] Rope slings, including end connections, are checked for excessive wear, broken wires, stretch, kinking, or twisting [5]
[ ] All functional operating mechanisms are checked for excessive wear of components [5]
[ ] Rope reeving is checked for noncompliance with manufacturer's recommendations [5]

B. Operational Tests [6]

[ ] Load hoisting and lowering mechanisms tested [6]
[ ] Boom hoisting and lowering mechanisms tested [6]
[ ] Swinging mechanism tested [6]
[ ] Travel mechanism tested [6]
[ ] Safety devices tested [6]

C. Load Test [3]

[ ] A load test using certified weights or scaled weights using a certified scale is conducted after each erection [3]
[ ] The load test is conducted in accordance with the manufacturer's instructions [3]
[ ] Where manufacturer's instructions are unavailable, the test is conducted in accordance with written load test procedures developed by a registered professional engineer [3]
[ ] Test loads do not exceed 110% of the rated load at any selected working radius [6]

D. Warning Device [4]

[ ] Crane is equipped with a gong or other effective warning signal [4]

E. Rated Capacity Chart [2]

[ ] A chart indicating the manufacturer's rated capacity at all operating radii for all permissible boom lengths and jib lengths with alternate ratings for optional equipment is posted [2]
[ ] Rated capacity charts are readily visible to the operator in the normal operating position [2]

IV. Final Steps

[ ] All guards have been reinstalled [7]
[ ] Safety devices reactivated [7]
[ ] Maintenance equipment removed [7]

V. Signatures

Inspector: _____________________________

Date: _________________________________

Supervisor: ___________________________

Date: _________________________________

7 source record(s)

Sources used for this answer

[1] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 29

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\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ - (d) Hoist or load attachment chains, including end connections, for excessive wear, twist, distorted links interfering with proper function, or stretch beyond manufacturer's recommendations. Visual inspection daily; monthly inspection with signed report. - (e) Rope slings, including end connections, for excessive wear, broken wires, stretch, kinking, or twisting. Visual inspection daily; monthly inspection with signed report. - (f) All functional operating mechanisms for excessive wear of components. - (g) Rope reeving for noncompliance with manufacturer's recommendations. - Periodic inspection . You must complete inspections of the crane at intervals as generally defined in (l)(b)(ii) of this section, depending upon its activity, severity of service, and environment, or as specifically indicated below. These inspections must include the requirements of (2) of this section and in addition, the following items. Any deficiencies such as listed must be carefully examined and determination made as to whether they constitute a safety hazard: - (a) Deformed, cracked, or corroded members. - (b) Loose bolts or rivets. - (c) Cracked or worn sheaves and drums. - (d) Worn, cracked or distorted parts such as pins, bearings, shafts, gears, rollers, locking and clamping devices. - (e) Excessive wear on brake system parts, linings, pawls, and ratchets. - (f) Load, wind, and other indicators over their full range, for any significant inaccuracies. - (g) Gasoline, diesel, electric, or other powerplants for improper performance or noncompliance with applicable safety requirements. - (h) Excessive wear of chain drive sprockets and excessive chain stretch. - (i) Crane hooks. Magnetic particle or other suitable crack detecting inspection should be performed at least once…

[2] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 48

Open source document

Source excerpt

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ WAC 296-24-[redacted postal code] (2)(b) before placing in service. - (c) You must inspect standby cranes at least semi-annually in accordance with requirements of subsection (2) of this section and WAC 296-24-[redacted postal code] (2)(b). Such cranes which are exposed to adverse environment should be inspected more frequently. - (5) Inspection records . You must make written, dated, and signed inspection reports and records monthly on critical items in use such as brakes, crane hooks, and ropes. You must keep records readily available. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 18-03-159 (Order 17-24), § 296-24-[redacted postal code], filed 01/23/2018, effective 02/23/2018. Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), § 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Statutory Authority: Order 73-5, § 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, § 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-[redacted postal code] Testing. ## (1) Operational tests . - (a) In addition to prototype tests and quality-control measures, the user of each new production crane must require that it be tested and related data supplied by the manufacturer to the extent necessary to ensure compliance with the operational requirements of this subsection including functions such as the following: - (i) Load hoisting and lowering mechanisms - (ii) Boom hoisting and lower mechanisms - (iii) Swinging mechanism - (iv) Travel mechanism - (v) Safety devices - (b) You must conduct such tests at final assembly where the complete production crane is not supplied by one manufacturer. - (c) You must make certified production-crane test results available. ## (2) Rated load te…

[3] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 46

Open source document

Source excerpt

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ - (ii) The crane must be standing on track which is level within 1% grade. - (iii) Radius of the load is the horizontal distance from a projection of the axis of rotation to the rail support surface, before loading, to the center of vertical hoist line or tackle with load applied. - (iv) Tipping loads from which ratings are determined must be applied under static conditions only, i.e., without dynamic effect of hoisting, lowering, or swinging. - (v) The weight of all auxiliary handling devices such as hoist blocks, hooks, and slings must be considered a part of the load rating. - (c) Stipulations governing the application of the values in (1)(a) of this section for crawler, truck, and wheel-mounted cranes must be in accordance with Crane Load-Stability Test Code. Society of Automotive Engineers (SAE) J765. Note: The effectiveness of these preceding stability factors will be influenced by such additional factors as freely suspended loads, track, wind, or ground conditions, condition and inflation of rubber tires, boom lengths, proper operating speeds for existing conditions, and, in general, careful and competent operation. All of these must be taken into account by the user. - (2) Rated capacity chart . You must post a chart indicating the manufacturer's rated capacity at all operating radii for all permissible boom lengths and jib lengths with alternate ratings for optional equipment affecting such ratings in all mobile type cranes. Rated capacity charts must be readily visible to the operator in the normal operating position. - (3) Inspection classification . Initial inspection. You must inspect all new and altered cranes prior to initial use to ensure compliance with provisions of these standards. - (4) You must ensure that all hooks are of the s…

[4] Rules for the Administration of the Oregon Safe Employment Act (Construction, Division 3, OSHA Oregon)

Page 1259

Open source document

Source excerpt

Oregon Occupational Safety and Health Division Oregon Administrative Rules AO 1-2019 Division 3 - (1) Site and ground bearing conditions. Site and ground conditions must be adequate for safe assembly/disassembly operations and to support the equipment during assembly/disassembly (see 1926.1402 for ground condition requirements). - (2) Blocking material. The size, amount, condition and method of stacking the blocking must be sufficient to sustain the loads and maintain stability. - (3) Proper location of blocking. When used to support lattice booms or components, blocking must be appropriately placed to: - (i) Protect the structural integrity of the equipment, and - (ii) Prevent dangerous movement and collapse. - (4) Verifying assist crane loads. When using an assist crane, the loads that will be imposed on the assist crane at each phase of assembly/disassembly must be verified in accordance with 1926.1417(o)(3) before assembly/disassembly begins. - (5) Boom and jib pick points. The point(s) of attachment of rigging to a boom (or boom sections or jib or jib sections) must be suitable for preventing structural damage and facilitating safe handling of these components. - (6) Center of gravity. - (i) The center of gravity of the load must be identified if that is necessary for the method used for maintaining stability. - (ii) Where there is insufficient information to accurately identify the center of gravity, measures designed to prevent unintended dangerous movement resulting from an inaccurate identification of the center of gravity must be used. (See Non-mandatory Appendix B of this subpart for an example.) - (7) Stability upon pin removal. The boom sections, boom suspension systems (such as gantry A-frames and jib struts), and components must be rigged or supported to maintain stability upon the removal of the pins. - (8) Snagging. Suspension ropes and pendants must not be allowed to catch on the boom or jib connection pins or cotter pins (including keepers and…

[5] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 28

Open source document

Source excerpt

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ - (h) You must ensure that replacement rope is 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. - Equalizers . You must ensure that the tension in the parts is equalized if a load is supported by more than one part of rope. - Hooks . You must ensure that hooks meet the manufacturer's recommendations and are not overloaded. Safety latch-type hooks must be used or the hook must be moused. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), § 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Statutory Authority: RCW 49.17.040, 49.17.050, 49.17.240, chapters 43.22 and 42.30 RCW. 80-17-015 (Order 8021), § 296-24-[redacted postal code], filed 11/13/80. Statutory Authority: RCW 49.17.040, 49.17.150, and 49.17.240. 79-08-115 (Order 79-9), § 296-24-[redacted postal code], filed 7/31/79; Order 73-5, § 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, § 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-[redacted postal code] Warning device. You must provide a gong or other effective warning signal for each crane equipped with a powered traveling mechanism except for floor operated cranes. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), § 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Order 73-5, § 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, § 296-24-[redacted postal code], filed 5/7/73.] ## WAC 296-24-[redacted postal code] Inspection. - Inspection classification . - (a) You must perform an initial inspection prior to initial use all new and altered cr…

[6] Rules for the Administration of the Oregon Safe Employment Act (Construction, Division 3, OSHA Oregon)

Page 1350

Open source document

Source excerpt

Division 3 AO 1-2019 Oregon Administrative Rules Oregon Occupational Safety and Health Division - (1) Section 1926.1412 (Inspections) applies to tower cranes, except that the term 'assembly' is replaced by 'erection.' Section 1926.1413 (Wire rope inspection) applies to tower cranes. - (2) Pre-erection inspection. Before each crane component is erected, it must be inspected by a qualified person for damage or excessive wear. - (i) The qualified person must pay particular attention to components that will be difficult to inspect thoroughly during shift inspections. - (ii) If the qualified person determines that a component is damaged or worn to the extent that it would create a safety hazard if used on the crane, that component must not be erected on the crane unless it is repaired and, upon reinspection by the qualified person, found to no longer create a safety hazard. - (iii) If the qualified person determines that, though not presently a safety hazard, the component needs to be monitored, the employer must ensure that the component is checked in the monthly inspections. Any such determination must be documented, and the documentation must be available to any individual who conducts a monthly inspection. - (3) Post-erection inspection. In addition to the requirements in 1926.1412(c), the following requirements must be met: - (i) A load test using certified weights, or scaled weights using a certified scale with a current certificate of calibration, must be conducted after each erection. - (ii) The load test must be conducted in accordance with the manufacturer's instructions when available. Where these instructions are unavailable, the test must be conducted in accordance with written load test procedures developed by a registered professional engineer familiar with the type of equipment involved. - (4) Monthly. The following additional items must be included: - (i) Tower (mast) bolts and other structural bolts (for loose or dislodged condition) from the base o…

[7] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 31

Open source document

Source excerpt

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ - (b) After adjustments and repairs have been made you must not operate the crane until all guards have been reinstalled, safety devices reactivated and maintenance equipment removed. ## Adjustments and repairs . - (a) You must correct any unsafe conditions disclosed by the inspection requirements of WAC 296-24-[redacted postal code] before operation of the crane is resumed. You must ensure that adjustments and repairs are done only by designated personnel. - (b) You must maintain adjustments maintained to ensure correct functioning of components. The following are examples: - (i) All functional operating mechanisms. - (ii) Limit switches. - (iii) Control systems. - (iv) Brakes. - (v) Power plants. - (c) You must provide repairs or replacements promptly as needed for safe operation. The following are examples: - (i) You must carefully examine accessory components, such as hooks, periodically and at the time of annual examination and inspection. You must discard cracked or deformed hooks immediately and not reused on any equipment subject to the provisions of this code. - (ii) Load attachment chains and rope slings showing defects described in WAC 296-24-[redacted postal code] (2)(d) and (e) respectively. - (iii) All critical parts which are cracked, broken, bent, or excessively worn. - (iv) You must keep pendant control stations clean and function labels kept legible. [Statutory Authority: RCW 49.17.010, .040, .050, and .060. 15-24-100 (Order 15-04), § 296-24-[redacted postal code], filed 12/01/2015, effective 01/05/2016. Statutory Authority: Chapter 49.17 RCW. 94-15-096 (Order 94-07), § 296-24-[redacted postal code], filed 7/20/94, effective 9/20/94; Order 73-5, § 296-24-[redacted postal code], filed 5/9/73 and Order 73-4, § 296-24-[redacted post…

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Publisher: SALUS
Final reviewer: Francis Langlois
Original answer: Jun 26, 2025

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Crane Assembly Safety Checklist

I. Pre-Assembly Inspection

A. Site and Ground Conditions

B. Blocking Material [1]

C. Component Inspection [3]

II. During Assembly

A. Assist Crane (if applicable) [1]

B. Boom and Jib Pick Points [1]

C. Center of Gravity [1]

D. Stability [1]

E. Wire Rope [4]

III. Post-Assembly Inspection and Testing

A. General Inspection [2]

B. Operational Tests [6]

C. Load Test [3]

D. Warning Device [4]

E. Rated Capacity Chart [2]

IV. Final Steps

V. Signatures

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Lifting a generator with a crane into place

ppe general industry

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