SANS10375 2018 Ed2

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ISBN-978-626-35768-9
SANS 10375:2018
Edition 2
SOUTH AFRICAN NATIONAL STANDARD
The inspection and testing of overhead

cranes
WARNING
This document references other
documents normatively.
Published by the South African Bureau of Standards

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SANS 10375:2018
Edition 2
Table of changes
Change No. Date Scope
Foreword
This South African standard was prepared by National Committee SABS/TC 096, Cranes, in
accordance with procedures of the South African Bureau of Standards, in compliance with
annexure 3 of the WTO/TBT agreement.
This document was approved for publication in March 2018.
This document supersedes SANS 10375:2006 (edition 1).
This document is referenced in the Occupational Health and Safety Act, 1993 (Act No. 85
of 1993).
Reference is made in 3.3 and 3.4 to the "relevant national legislation". In South Africa this means the
Engineering Profession Act, 2000 (Act No. 46 of 2000).
Reference is made in 3.4 to the "relevant national body". In South Africa this means the engineering
council of South Africa.
Reference is made in 3.5 to "the relevant national legislation". In South Africa this means the
Occupational Health and Safety Act, 1993 (Act No. 85 of 1993).
Annexes A, D, F and G form an integral part of this document. Annexes B, C, E, H and I are for
information only.
Compliance with this document cannot confer immunity from legal obligations.
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Contents
Page
Foreword
1 Scope ..................................................................................................................................... 3
2 Normative reference .............................................................................................................. 3
3 Definitions .............................................................................................................................. 3
4 Personnel ............................................................................................................................... 5
5 Facilities, information, equipment and precautions ................................................................. 6
6 Inspections .............................................................................................................................. 7
6.1 General........................................................................................................................... 7
6.2 Daily inspections ............................................................................................................ 7
6.3 Frequent inspections ..................................................................................................... 8
6.4 Periodic thorough inspections ........................................................................................ 8
6.5 Exceptional inspections .................................................................................................. 11
6.6 Major inspections ........................................................................................................... 12
6.7 Examination scheme approach ...................................................................................... 13
6.8 Testing............................................................................................................................ 13
7 Major or structural repairs or modifications to load path ......................................................... 15

7.1 General........................................................................................................................... 15
7.2 Testing after major repair of or modification to the load path ......................................... 15
8 Non-destructive testing ........................................................................................................... 15
9 Documentation ........................................................................................................................ 16
9.1 Reports ........................................................................................................................... 16
9.2 Records .......................................................................................................................... 17
Annex A (normative) Inspection precautions .............................................................................. 18
Annex B (informative) Daily inspection checklist ........................................................................ 19
Annex C (informative) Frequent inspection checklist.................................................................. 20
Annex D (normative) Lifting of persons – Inspection and testing of cranes and

lifting accessories ......................................................................................................... 21
Annex E (informative) Verification of hooks ................................................................................ 25
Annex F (normative) Examination scheme approach ................................................................. 26
Annex G (normative) Test procedure ......................................................................................... 28
Annex H (informative) Certificate of inspection/testing of overhead crane ................................. 29
Annex I (informative) Non-destructive testing — Most common types ....................................... 31
Bibliography .............................................................................................................................. 32
1
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The inspection and testing of overhead cranes
1 Scope
1.1 This standard covers provisions for the inspection, testing and examination of overhead cranes
in use.
1.2 This standard does not cover the inspection, testing and examination of new or refurbished
overhead cranes (see SANS 4310).
2 Normative reference
The following referenced documents, in whole or in part, are normatively referenced in this
document and are indispensable for its application. For dated references, only the edition cited
applies. For undated references, the latest edition of the referenced document (including any
amendments) applies. Information on currently valid national and international standards can be
obtained from the South African Bureau of Standards.
EN 14502-1, Cranes – Equipment for lifting of persons – Part 1: Suspended baskets.
ISO 4306-1, Cranes – Vocabulary – Part 1: General.
SANS 687, Inspection and testing of non-fixed load-lifting attachments.
SANS 4310, Cranes – Test code and procedures.
SANS 12482-1/ISO 12482-1, Cranes condition monitoring – Part 1: General.
3 Definitions
For the purposes of this document, the definitions in ISO 4306-1 and the following definitions apply.
3.1
brake
device for reducing the speed or stopping or preventing movement of the crane mechanisms (or all
of these)
3.2
competent person
person who has the knowledge, training, experience and qualifications specific to the work or task
being performed
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3.3
expert engineer
engineer as specified in the relevant national legislation (see foreword) who has experience in the
design, construction or maintenance of overhead cranes, sufficient knowledge of the relevant
regulations and standards and the equipment and who is in a position to judge the safe condition of
the crane and to decide which measures shall be taken in order to ensure continued safe operation
3.4
crane inspector
lifting machinery inspector
LMI
person who is responsible and competent to perform inspections and test according to acceptable
standards and legislation as specified in the relevant national legislation (see foreword) and with a
valid registration as a lifting machinery inspector in accordance with the relevant national body (see
foreword)
3.5
crane operator
person who is certified to operate a crane for the purpose of positioning loads or for the erection of
the crane as specified in the relevant national legislation (see foreword)
3.6
designated person
person who possesses relevant knowledge and experience in the field of overhead cranes and is
assigned by the employer to carry out any supervision or inspection on overhead cranes
3.7
crab
crab trolley
assembly designed to traverse the suspended load whether on top-running or underslung girders
3.8
design authority
organization responsible for establishing the design requirements and ensuring that design output
documents accurately reflect the actual design.
NOTE 1 The design authority is responsible for design control and ultimate technical adequacy of the design
process. These responsibilities are applicable whether the process is conducted fully in-house, partially
contracted to outside organizations, or fully contracted to outside organizations. The design authority may
delegate design work, but not its responsibilities.
NOTE 2 This is applicable where the manufacturer seizes to exist.
3.9
emergency brake
additional brake system designed to stop all movement of the crane including emergency over-
speed brake
3.10
lifting
movement of loads or persons necessitating, at a given moment, a change of level
3.11
lifting accessories
lifting tackle for attaching loads to machinery for lifting purposes and include non-fixed lifting
attachments
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3.12
load path
all components involved in supporting the load being lifted
3.13
major repair or modification
material alteration or repair of the load path from the original manufacturer’s design
3.14
non-destructive testing
NDT
testing technique carried out on the structure and components of the crane to establish the
presence, location and extent of any defects that can affect the integrity of that structure such that it
does not damage or alter the material under the test
NOTE NDT is also known as non-destructive examination (NDE).
3.15
record book
document that is used to record the specification and also all incidents, modifications, repairs,
inspections and testing of the crane
3.16
safe working load
SWL
maximum load that can be safely handled by an overhead crane
3.17
testing
3.17.1
functional testing
operation of each motion of the crane without the application of a load in order to determine
whether the equipment performs as the manufacturer intended
3.17.2
performance testing
operation of each motion of the overhead crane with the safe working load (SWL) applied in
order to determine whether the equipment performs to the manufacturer's requirements
3.17.3
overload testing
operation of the overhead crane with an applied load exceeding the SWL in order to determine
whether the crane is structurally sound and fit for the use it was intended
3.18
user
person or organization that has control of both the lifting operation and the crane operator, and has
a responsibility to ensure that cranes and other equipment are properly maintained, inspected and
tested
4 Personnel
4.1 Inspection and testing shall be carried out by a competent person.
4.2 If, whilst carrying out an inspection, a competent person sees that the overhead crane or lifting
accessories are not safe for any reason, this, in addition to defects caused by deterioration, shall be
reported to the user.
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4.3 Where the competent person identifies defects that need to be rectified within a specified
period of time, he/she shall promptly submit a report to allow the user to take the necessary action
within the required period.
5 Facilities, information, equipment and precautions

5.1 Facilities
The crane user shall ensure that the facilities required by the competent person to carry out the
inspection and testing are provided. These may include the following:
a) an appropriate area, cordoned off to prevent access by persons not directly involved in the
inspection;
b) a crane operator; or
c) the preparation of parts or areas of the crane for examination and NDT.
5.2 Information
A crane record book, containing all relevant information shall be made available to the competent
person (see 9.2).
5.3 Equipment
5.3.1 Measuring equipment
All measuring equipment shall have a valid calibration certificate and shall be accurate to within
0,5 % of the measured value, and shall be undamaged and properly maintained.
5.3.2 Test weights
The test weights shall be
a) weights of proven accuracy to within ± 1,0 %;
b) weights proven on a weighbridge, the weighbridge having been calibrated within the last twelve
months; or
c) weights suspended from a calibrated weighing device, the weighing device having been
calibrated within the last twelve months. The weighing device shall be capable of weighing the
test load to within ± 1,0 %.
5.3.3 Precautions for inspection
The safety of the personnel involved in the crane inspection shall be in accordance with
SANS 12482-1 and annex A.
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6 Inspections
6.1 General
6.1.1 Inspections shall be carried out at a frequency to enable the crane to be kept in a safe and
satisfactory condition.
6.1.2 Where instructions for inspection and maintenance of the manufacturer are available, they
shall be assessed by a competent person against the requirements of this standard. Where they are
determined to be adequate and appropriate, they shall be applied to the crane's inspections.
6.1.3 Where the instructions for inspections of the manufacturer are not available, or are deemed
inappropriate or inadequate by a competent person, the applicable provisions of this standard shall
apply.
6.1.4 Inspections shall be carried out in accordance with the requirements of this standard and
instructions written in accordance with this standard. All such work shall be noted in the records.
6.1.5 The instructions shall be written in plain language and shall be made available to all persons
carrying out inspections.
6.1.6 Information on, for example, SWL, alterations, maintenance repairs, renewals and operators’
instructions, shall be made available to the competent person if these are necessary to carry out the
inspections.
6.1.7 Lifting accessories shall be included in the inspection regime. The requirements for non-fixed
lifting attachments are specified in SANS 687.
6.1.8 The following inspections are applicable:

a) daily inspection;
b) frequent inspection;
c) periodic thorough inspection;
d) examination scheme approach;
e) exceptional inspection; and
f) major inspection
6.2 Daily inspections

6.2.1 Before the commencement of each work shift, the crane shall be given a visual inspection
and functional test to find evidence of deficiencies.
6.2.2 All safety-related problems shall be recorded, reported and resolved, before the crane is
used.
6.2.3 Such inspections and testing may be carried out by the crane operator and should include the
items listed in annex B.
6.2.4 The functional tests shall be conducted without load where appropriate from the control
station.
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6.3 Frequent inspections

6.3.1 Frequency of inspection shall be based upon the frequency and severity of use of the crane
while in service and the working environment, for example temperatures, dust, chemicals.
6.3.2 The inspection shall be carried out by a designated person (for example, an experienced
technician) at no more than three-monthly intervals unless the crane is not in-service. It shall not be
inferred that dismantling of any part is necessary during this inspection but opening of covers (for
example, limit switch covers), which are required for service and inspection purposes, shall be
included.
6.3.3 The inspection procedure shall include verification that the current logbook and operators’
manual(s) are available and that this documentation is up-to-date.
6.3.4 A checklist of items, which should be included in the inspection is given in annex C.
6.3.5 A written report shall be furnished on completion of the inspection. The crane shall not be
returned to service until all safety-related malfunctions and problems have been corrected. (All work
history of replaced parts or modifications should be recorded for each service history)
6.4 Periodic thorough inspections
6.4.1 General
6.4.1.1 Cranes that are used to lift persons shall be examined by a crane inspector at least once
every six months, or at a shorter interval if so specified by the crane inspector and include the lifting
accessories in accordance with annex D.
NOTE Cranes lifting people should not be subjected to an overload test during the six monthly inspections
unless required by a crane inspector.
6.4.1.2 Work platforms shall comply with EN 14502-1.
6.4.1.3 Cranes that are not used to lift persons shall be examined by a crane inspector at least
once every twelve months.
6.4.1.4 After carrying out the periodic inspections, the crane inspector shall specify when the next
inspection is to be carried out, which may be less than, but not more than, twelve months later.
6.4.1.5 Before the inspections, the crane shall be cleaned by appropriate means (for example,
pressure washed), to remove all spilt matter and dirt that would otherwise conceal the structure or
mechanisms and prevent an effective examination.
6.4.1.6 The examination shall be carried out in a logical sequence, for example, top to bottom, to
ensure that nothing is overlooked.
NOTE The crane inspector is responsible for the crane only and does not include the civil structure on which
the crane is mounted.
6.4.1.7 Particular attention shall be given to the following:
a) vibration;
b) unusual noise or temperature;
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c) poor general condition, corrosion;
d) alignment of machinery, motor and gears, rails, wheels, shafts; and
e) load rope condition.
6.4.2 Checks and tests to be carried out

The following checks and tests (as relevant) shall be carried out:
a) Verify that the record book is available, corresponds to the equipment being examined and is
complete.
b) Determine if there is any history of defects or malfunctions, and whether any repairs, alterations
or additions have been made. The last report of thorough examination shall be consulted.
c) Functionally test all limit switches, including the hoist, long travel, cross travel and proximity, for
correct operation.
d) Functionally test all operator controls for smoothness of operation and freedom from wear and
other damage.
e) Operate the crane through all the motions. Listen for any sounds that might indicate defects and
observe any other malfunctions.
f) Confirm if the crane has been made safe by isolating the power, when necessary, and reinstating
it, as appropriate.
g) Examine the general appearance and condition of the crane.
h) Examine the structure of the crane for damage, cracks, wear, distortion, corrosion and missing
parts, including the following parts:
1) end carriages;
2) bridge girders, and their mechanisms;
3) crabs;
4) gantry rails;
NOTE These are the whole length of the long travel and cross travel.
5) bolts and fasteners to verify that they are not coming loose; and
6) end stops and buffers;
i) Examine the long travel and cross travel mechanisms for damage, cracks, wear, alignment,
distortion, corrosion, missing parts and lubrication, including the following parts:
1) motor;
2) gearing;
3) transmission machinery;
4) bearings;
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6) long travel or cross travel wheels, as relevant;
The maximum allowable flange wear shall be 50 % of original thickness.
NOTE Pinholes or slots usually indicate residual thickness of 50 %.
8) gear cases;
9) covers and guards; and
10) brakes and storm brakes
The wear of brake drum diameter shall be determined by the manufacturer. In the absence, the
maximum allowable wear shall be 2 % of the original diameter. Brake drums with uneven wear,
cracks or other deterioration shall be replaced immediately.
j) Examine the hoist mechanism for damage, cracks, wear, alignment, distortion, corrosion, missing
parts and lubrication, including the following parts:
1) motor;
2) gearing;
3) transmission machinery especially couplings;
4) bearings;
5) rope-spooling mechanism;
7) hoist drum;
8) gear cases; and
7) covers and guards; and
8) brakes
Emergency over-speed brakes shall not be tested dynamically except according to the
recommendations of the manufacturer. Inspection should include measuring the required air gap
between the brake and the flange.
k) Examine all wire ropes or chains, anchorages and their fittings. (for wire ropes apply the
requirements of SANS 4309)
l) Examine the hook or bottom or return block assembly for damage, seizure, alignment, cracks,
wear, distortion, corrosion, missing parts and lubrication.
NOTE For verification of hooks (see annex E).
m) Examine the cab and seating for security, integrity and tidiness.
n) Examine the controls (including the pendent and cableless controls) for markings of their
functions and modes of operation.
o) Examine the audible and visual warning devices for damage, security and integrity, and
functionally test the warning devices for correct operation.
p) Examine all limit switches for damage, security and integrity.
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q) Examine the platforms and access ladders for damage, corrosion, integrity and security,
obstructions and tidiness, and
r) Examine the electrical system for integrity, deterioration, damage and security, including the
following:
a) isolators;
b) motors;
c) leads and collectors;
d) lighting;
e) wiring;
f) catenaries; and
g) trailing cables.
6.5 Exceptional inspections

6.5.1 Exceptional inspections shall be performed by an expert engineer.
6.5.2 Exceptional circumstances include the following:

a) collision with other structures;
b) overload or engineered lift;
c) safety device failure;
d) fire;
e) earthquake or seismic condition; or
f) extreme weather conditions;
6.5.3 Consideration to repair damaged components or change of the following:

a) load rating;
b) load bearing mechanical or structural components;
c) hoisting mechanism;
d) control station and system;
e) prime mover, for example long travel, cross travel;
f) wire ropes or chains;
NOTE (Only if there is a change in the physical or material properties of the rope i.e. change in diameter
or breaking strength).
g) fixed and non-fixed load-lifting components.
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6.6 Major inspections
6.6.1 The following categories of cranes shall be subjected to a major inspection and associated
maintenance according to the requirements of SANS 12482-1:
a) cranes where the examination scheme approach regime has not been carried out and the cranes
have been in use for a period of twenty years or reached the end of the design life, whichever
comes first; and
b) cranes that are to be re-commissioned or imported and that do not have previous continuous
working records and maintenance records.
6.6.2 The major inspection shall involve examination of those critical components identified by the
manufacturer or a crane inspector. Where necessary, the crane shall be stripped down and paint,
grease and corrosion removed from critical components to allow a complete and thorough
inspection.
6.6.3 Particular attention shall be given to the following:
a) past state of loading and utilization as compared to the crane's classifications;
b) future intended state of loading and utilization as required by the user of the crane;
c) structural, mechanical, electrical, instrumentation, control and operational anomalies;
d) non-destructive testing of all nominated critical areas for evidence of cracking due to fatigue and
excessive stress;
e) components whose maintenance records indicate repeated failures;
f) controls and emergency stop;
g) braking systems;
h) platform levelling systems;
i) platform, handrails and gate;
j) adequacy of safety instructions and manuals for operation and maintenance;
k) manufacturer’s safety upgrades; and
l) emergency retrieval system;
6.6.4 A written report shall be furnished on completion of the inspection. An expert engineer shall
assess the results and
a) specify the defects and wear where attention is necessary to ensure its continued safe operation,
and
b) identify components that require particular attention in subsequent periodic inspections.
6.6.5 The crane shall not be returned to service until all safety-related malfunctions and problems
have been corrected.
6.6.6 Following the major inspection, the crane shall either be subjected to the program for
inspection as part of inspections specified in 6.2 to 6.4 or subjected to the examination scheme
approach.
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6.7 Examination scheme approach

6.7.1 The examination scheme approach to inspection and testing, if used, shall be based on
regular assessments of the crane in accordance with its usage. The competent person should take
into account the age, loading, environmental and duty cycle history of the crane, and any
examination intervals which have traditionally been accepted as appropriate for that or similar
equipment. Equipment that does not have a complete record of past usage shall be subjected to
periodic inspection.
6.7.2 The requirements are specified in annex F .
6.8 Testing
6.8.1 General
6.8.1.1 Overhead cranes shall be tested every twelve months by a crane inspector.
6.8.1.2 Inspection of the crane according to 6.4 shall be carried out before any test commences.
6.8.1.3 Test shall not be conducted in wind speeds that are in excess of those specified in the
operating instructions for the crane. The limiting wind speed is reduced during overload testing.
Advice shall be obtained from the manufacturer of the crane or other appropriate authority before
carrying out overload testing.
6.8.1.4 The test site shall be of sufficient area to eliminate any risk to personnel.
6.8.1.5 All personnel not essential to the test shall be kept away from the area. The test area shall
be roped off and notices shall be posted prohibiting unauthorized entry. The site shall be clear of
plant and property which could inhibit the test.
6.8.1.6 The maximum deflection of the crane shall not exceed any prior recorded deflections taking
into account the accuracy of the test load and measuring instruments. See 5.3 for the required
accuracies.
6.8.1.7 The deflection shall not be considered as an indication of the possible load bearing capacity
of the crane.
6.8.1.8 Load tests shall be conducted in accordance with the procedure given in annex G.
NOTE Load testing is designed to prove a crane. However, the crane might not withstand the loading.
6.8.2 Functional test
6.8.2.1 Functional testing shall be carried out on all functions of the crane, including controls
(including any remote controls), contactors, brakes and safety devices. The adjustments of the
brakes and limit shall be checked and tests shall be carried out to determine whether they are
operating correctly.
6.8.2.2 The functional test shall be performed without a load to confirm correct and smooth
operations and whether the equipment performs as the manufacturer intended.
NOTE It might be necessary to include the lifting of a suitable load once these devices have been tested.
6.8.2.3 The equipment shall be free from wear and other damage.
6.8.3 Performance test
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6.8.3.1 Performance testing shall be carried out after functional testing. The cranes shall be
operated with 100 % SWL having been applied.
6.8.3.2 Performance testing shall be carried out on all functions of the crane, including brakes and
safety devices to determine whether the equipment operates correctly and smoothly at the
maximum speed.
6.8.3.3 The equipment shall be free from wear and other damage.
6.8.4 Overload test
6.8.4.1 Overload testing shall not be performed during the normal performance of inspection and
testing of overhead cranes in service.
6.8.4.2 Overload testing may only be performed under the supervision of an expert engineer in order
to proof load test either a new or refurbished crane in accordance with the requirements of the
manufacturing or refurbishment design standard. In the case of a refurbishment, details of the repair
or refurbishment shall be recorded in the crane record book along with the results of the test.
6.8.4.3 Overload testing of new cranes may only be performed by an LMI in order to proof load test
the crane in accordance with the requirements of the manufacturing design standard. Details of the
results shall be recorded in the crane record book.
6.8.5 Limiting and indicating devices
6.8.5.1 Limiting and indicating devices shall be tested to ensure the operation is within the
tolerances permitted by the manufacturer.
6.8.5.2 All calibration of the devices shall be performed by a competent person and the calibration
certificate issued. This certificate shall be reviewed by the LMI as part of the inspection.
6.8.5.3 A test shall be performed to prove the activation of the load limiting device. A load of not
more than 110 % of the SWL shall be used.
6.8.6 Post-test inspections and certification
6.8.6.1 On completion of the tests, an examination shall be carried out by the crane inspector to
determine whether the crane has withstood testing without signs of structural damage that could
affect the safety of the crane, such as
a) cracking,
b) permanent deformation,
c) paint flaking, and
d) loosening of or damage to structural connections.
6.8.6.2 After completion of the test, the crane inspector shall issue the appropriate certificate, which
shall be appended to the report of inspection. All results and findings shall be recorded in the record
book in the form of a report (see clause 9 and annex H).
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7 Major or structural repairs or modifications to load path

7.1 General
7.1.1 Any major repairs or modification to the load path of a crane shall be in accordance with the
manufacturer's specifications or a design authority. This includes the increase of the SWL.
7.1.2 Either the original manufacturer or a design authority shall be appointed.
7.1.3 The entity specifying the major repair or modification shall have a quality system which
includes at least the following:
a) a design drawing indicating the repairs or modifications and shall include the following but not
limited to
1) calculations,
2) materials,
3 weld procedures,
4 electrical components, and
5) mechanical components
b) verification of the repair process, for example. use of coded welders, non-destructive testing,
c) verification of the testing after major repairs or modifications according to 7.2, and
d) all relevant documentation shall be added to the records of the crane.
7.2 Testing after major repair of or modification to the load path

7.2.1 Equipment shall be thoroughly examined and tested after every major repair of or
modification to the load path as though it was a new crane.
7.2.2 Any testing shall be carried out in accordance with the requirements of the design standard in
accordance to which the modification or repair was done as well as any additional written
instructions from the manufacturer or appropriate design authority.
7.2.3 In the event of any alteration or repair that could affect the strength of the crane, overload
testing shall be carried out to ensure that all parts affected by the repair are subjected to the test
loads in accordance with the original crane specification, or SANS 4310 (or both).
8 Non-destructive testing
During the thorough inspections of a crane, the crane inspector might consider it appropriate to
apply NDT techniques to assess the integrity of components. These techniques can assist in the
detection of any material cracks or defects that might grow in service and ultimately lead to failure.
For different types of testing see annex I.
NOTE SANS 9712 contains guidance on the qualification and certification of NDT personnel and, unless the
operator is working to a detailed written procedure, he or she should be qualified to level two in accordance
with SANS 9712.
© SABS 15
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9 Documentation
9.1 Reports
After every thorough inspection (including when a crane is tested), a report shall be prepared. The
report shall contain at least the following information:
a) the name and address of the user;
b) the physical address of the premises where the inspection or test (or both) was conducted;
c) description of the crane, for example. make and type
d) date of manufacture of crane;
e) identification or serial number of crane;
f) SWL of crane (auxiliary hoist(s) shall be included);
g) the date of the previous test;
h) date of previous thorough inspection;
i) whether it is a thorough inspection or test (or both)
1) within an interval of six months,
2) within an interval of twelve months,
3) in accordance with an examination scheme,
4) after the occurrence of exceptional circumstances,
5) after major inspections or
6) after major repairs or modifications to the load path
j) the date on which the inspection or test (or both) was done;
k) the date of the report;
l) in relation to every inspection or test (or both):
1) identification of any part found to have a defect which is, or could become, a danger to
persons and the safe operation of the overhead crane, and a description of the defect;
2) recommendations (if within the crane inspector’s competence) of any repair, renewal or
alteration required to remedy a defect found to be a danger to persons or the safe operation
of the overhead crane (or both);
3) in the case of a defect which is not yet, but could become, a danger to persons or to the
safe operation of the overhead crane (or both)
i) the time by which it could become such a danger, if known, or an appropriate monitoring
process (or both); and
ii) recommendations (if within the inspector’s competence) of any repair, renewal or
alteration required to remedy it;
16 © SABS
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m) a statement to the effect that the overhead crane is safe to be operated; that the overhead crane
was properly inspected or tested (or both) and that the overhead crane is certified for use for a
further period, or not;
n) the date and type of the next inspection or test (or both);
o) the full contact details of the entity performing the test;
p) the registration number of the entity; and
q) full particulars of the person performing the inspection or testing (or both).
NOTE An example of an inspection or test certificate (or both) is given in annex H.
9.2 Records
9.2.1 The user shall have records of full particulars of any performance test and inspections, any
modification or repair of the overhead crane and shall be readily available. They may be in any
suitable format. These records shall be transferred with ownership of the crane.
9.2.2 The records that shall be retained in the logbook are copies of but not limited to
a) all documentation received from manufacturer, for examples instruction manual, certificate of
conformity, parts lists;
b) the last major inspection;
c) the last periodic thorough inspection;
d) the last test;
e) the last frequent inspection; and
f) the complete daily pre-operation reports for not less than the last 90 days of operation, or since
the last frequent inspection whichever is the greater;
g) action taken or repairs carried out to rectify malfunctioning or damaged components; and
h) any modifications.
9.2.3 Each log entry shall be signed by the responsible person making the entry and should contain
details of that person’s identification and qualifications.
9.2.4 The checks, adjustments, replacement of parts, repairs and inspections performed and all
irregularities or damage concerning the unit’s safe use shall be recorded.
9.2.5 In addition, all complete reports for all inspections shall be maintained and made available for
examination as required.
NOTE Any system that records these events and is readily available to the operator and inspector should be
accepted as meeting the intent of 9.2.
© SABS 17
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Annex A
(normative)
Inspection precautions
The following precautions shall be taken prior to and during inspection:
a) The place of inspection and its vicinity shall be checked to ensure that the inspection is carried
out safely.
b) When hazards are predicted due to extreme weather conditions, the inspection shall be
postponed until the weather improves.
c) Where required, inspection personnel shall use personal protective equipment, such as a hard
hats, safety harnesses or safety glasses, at the site of inspection.
d) In order to protect users from electric shocks, the tools used during inspection shall be of safe
construction.
e) Wherever they may be exposed to the danger of falling from a height during the inspection,
inspection personnel shall be properly guarded including by the use of safety harnesses,
elevating work platforms and man cages.
f) It shall be indicated at the control station of the crane under inspection that the inspection is in
progress.
g) When inspecting electrical parts, electrical circuits, power sources or power switches (or both)
shall be deactivated.
h) During the inspection, the activation and de-activation of power switches shall be strictly
prohibited except when instructed by the inspection person.
i) When entering a place where there is a danger of electric shock during the inspection, the power
switch shall be in the off position and locked or tagged out. It shall be indicated on the control
station that the inspection is in progress.
j) During the inspection, crane operation shall be strictly prohibited except when instructed by the
inspection person.
k) When two or more cranes are installed in the same long travel, measures shall be taken to
prevent the movement of the other cranes near the crane under inspection.
l) Prior to the load test, the sling attachments and test load shall be checked for any defects.
m) The inspection personnel and other personnel in the vicinity shall be strictly prohibited from
entering the nip points.
18 © SABS
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Annex B
(informative)
Daily inspection checklist
Visual inspection
Component Functional test
(Where practical)
Pendant and cab controls x x
Limits – Upper/Lower, 3 windings, proximity (where
– x
applicable/practical)
Visual and audible alarms x
Personal protective equipment x –
Cables and wiring for security and damage x –
Access and egress (ladders/stairs/emergency) x –
Loose and missing parts/bolts/nuts x –
Brakes – x
Wheels and rails x –
Placards, decals, warnings, control markings x –
Safety switches and interlocks x
Structural defects or damage x –
Correct operation of drive and speed functions,
– x
including speed-limiting devices
Steel wire ropes & bottom block x –
Lifting accessories x –
© SABS 19
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Annex C
(informative)
Frequent inspection checklist

The following should be inspected as minimum:
a) All functions and their controls for speed, smoothness of operation and limits of motion.
b) All emergency and safety devices including interlocks and emergency lowering devices.
c) Pendant and cab controls including the provisions for overriding of additional controls.
d) Hooks and latches. See annex E for guidance.
e) Steel wire rope or chains and lifting accessories.
f) All chain and cable mechanisms for adjustment wear and damage.
g) Lubrication of all moving parts, inspection of filter element (s) and fluid levels.
h) Visual inspection of structural members and welds.
i) Visual inspection, and measurements as necessary, of critical components such as brakes,

gears, fasteners, pins, shafts, wire ropes, sheaves, locking devices, all guardrails and guarding,
all attachments and connections and all ancillary equipment.
j) Electrical installation including contactors, isolators; motors; leads and collectors; lighting; wiring;
catenaries and trailing cables.
k) Signage, including warning signs, decals and control markings.
l) Wear and damage to wheels and rails.
m) Corrosion.
20 © SABS
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Annex D
(normative)
Lifting of persons — Inspection and testing of cranes

and lifting accessories
D.1 General
Cranes and other equipment used to lift persons and the personnel work platform shall be
thoroughly examined either at least every six months or in accordance with a written scheme of
thorough inspection.
D.2 Crane
D.2.1 Check to ensure that the crane has an appropriate duty for personnel lifting (i.e. half the
SWL for lifting other loads).
D.2.2 Check to ensure that the crane is equipped with a motion-control system that brings motion
to rest automatically when the controls are released.
D.2.3 Check to ensure that the crane is equipped with an appropriate anemometer or other device
to monitor in-service wind speeds. This is intended to ensure that personnel work platforms are not
used in wind speeds in excess of 7 m/s.
D.2.4 Carry out a functional check to determine whether the crane control system is able to
provide a smooth transition of the work platform. The control shall be such that the work platform
can proceed gently and the working speed shall not exceed 0,5 m/s during all motions.
D.2.5 Check to ensure that means are provided so that, if the power supply or control system fails,
the work platform can be positioned to enable access/egress without risk.
D.2.6 Measure the wire rope used for hoisting and lowering the work platform. The wire rope shall
have a diameter of at least 8 mm.
D.3 Work Platform

D.3.1 Visually check to ensure that storage accommodation for equipment, including any
emergency egress equipment (for example, safety harness, lanyard), is provided in the work
platform.
D.3.2 Visually check to ensure that the work platform is marked with the number of persons that
may be carried and the maximum load that may be carried.
D.3.3 Check to ensure that doors in the work platform open inwards and that doors can be
securely fastened.
D.3.4 Visually check to ensure that the work platform has hand rails, mounted in positions that do
not trap hands, to provide security for persons.
D.3.5 Visually check to ensure that the work platform sides are such as to prevent persons or
materials from falling from the work platform.
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D.3.6 Visually check to ensure that any attachment points for safety devices such as harnesses
are secure and undamaged.
D.3.7 Visually check any safety devices such as harnesses and lanyards for integrity and
completeness.
D.3.8 Visually examine the structure of the work platform. It shall be free from damage, corrosion,
cracks and other imperfections.
D.3.9 Visually check any mechanism provided to ensure that the floor of the work platform remains
horizontal. It shall be free from damage, leaks, corrosion and wear.
D.3.10 Visually check the work platform for a unique identification mark and record this on the
report of thorough inspection.
D.4 Report of thorough examination

The report of thorough inspection shall state that the crane and work platform have been thoroughly
examined for the purpose of lifting persons.
D.5 Bosun's chair

D.5.1 Visually examine both primary and secondary suspension points. They shall be free from
damage, corrosion, cracks and other imperfections.
D.5.2 Visually examine the seat structure for damage, security and contamination.
D.5.3 Visually examine the seat belt(s) for damage, contamination, security of their fixings and
correct operation.
D.6 Harnesses
D.6.1 Visually examine the harness for signs of cuts, abrasion, damaged stitching or
contamination.
D.6.2 Check the harness for correct operation of all buckles, adjusters, fasteners, etc.
D.6.3 Visually examine both primary and secondary suspension points. They shall be free from
damage, corrosion, cracks and other imperfections.
D.6.4 Check the age of the harness to determine whether it is within the age range recommended
by the manufacturer.
D.6.5 Check the harness for the correct capacity.
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D.7 Pre-use checks

D.7.1 Crane
Before using the crane for lifting persons and suspended work platform, ensure that the following
requirements have been complied with:
a) the hoist ropes are free of kinks and other obvious defects;
b) a means has been provided to prevent the work platform attachment from becoming detached
from the hook;
c) multiple part lines are not twisted around one another;
d) there is no slack in the wire ropes; and
e) all ropes are properly seated on drums and on sheaves.
D.7.2 Work platform
D.7.2.1 The work platform, suspension system, attachment points and any work platform motion
controls shall be checked before use by the appointed person or crane supervisor. The checks are
to identify conditions that have been specifically indicated by the work platform manufacturer, or
crane inspector, as potentially creating a hazardous operating condition.
D.7.2.2 The checks shall cover at least those items listed in the checklist in D.8, and the form shall
be signed by the appointed person/crane supervisor. Any conditions found to be unsatisfactory shall
be corrected before persons are lifted.
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D.8 Personnel carrier — Pre-use check
Inspector: Date:
Platform ID:
Marking Satisfactory Unsatisfactory
Platform (all information legible)
Make of platform
Date of manufacture
Safe working load
Number of people licensed to carry
Certificate issued by Department of Labour
Last inspection/examination
Suspension system
Structure
Load-supporting welds/bolts
Load-supporting members
Barrier from toe board to intermediate rail
Hand rail
Fall protection device
Anchorage points
Gate-locking mechanisms
Platform flooring
Suspension attachment points
Attachment mechanisms
Pins/eyes
Wire rope/chain
Master links and shackles
Special-purpose items (e.g. overhead protection, platform controls)
1
2
3
4
General comments:
Weather conditions and lighting:
Appointed person/crane supervisor:
Name (print)…………..................………………Signature…………………............................…………..Date……................
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Annex E
(informative)
Verification of hooks
To apply the following method, the initial dimensions of the hooks need to be known. The
dimensions are available from the manufacturer of the crane or the hook.
a) Deformation: If the opening "a" and "y" have widened more than 10 %, which is the maximum
permissible limit, replace the load hook.
b) Surface fissures
Damage and surface fissures may be removed notch-less, provided that the permissible
tolerance levels are not exceeded.
c) Wear
Wear on single or twin hooks may not be greater than 5 % of the height "h". It is not permitted to
carry out welding work on load hooks, for example, to compensate for wear.
d) Hook neck shaft

Cracks
© SABS 25
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Annex F
(normative)
Examination scheme approach
F.1 The examination scheme shall include a written schedule of the steps required to periodically
assess the condition of items included in the examination, for example, condition monitoring. The
scheme is intended to ensure that the equipment remains safe to use and includes information on
the required frequency of examinations.
F.2 The crane inspector shall prepare an examination scheme which might require the co-
operation of the equipment manufacturer and user. For example, the manufacturer might provide
limiting criteria based on the crane design, number of load cycles, load spectrum, critical parts and
exceptional circumstances (such as shock loading). These criteria should not be based on time
alone.
F.3 The crane inspector should take into account the limiting criteria from the crane supplier when
devising an examination scheme in accordance with the relevant national regulations for lifting
equipment.
NOTE Data-logging equipment greatly facilitates the collection of information concerning crane usage for
comparison with the crane design criteria. The data-logging equipment needs to be fitted to the crane when it
is new to ensure that a complete record of all the usage of the crane is maintained.
F.4 An examination scheme shall contain at least the following information:
a) The name and address of the owner.
b) The name, qualifications and address of the person drawing up the scheme and certifying that it
is suitable and sufficient. If the crane inspector is not working on his/her own account, the name
of the organization employing him/her and his/her position in that organization.
c) The make, model and unique identification number of the crane.
d) Any information used in drawing up the scheme. This might include the instructions, or specific
information from the designer on the design life of the structure and mechanisms.
e) Details of any data-logging system fitted, including a listing of the parameters monitored and the
means by which data retrieval, monitoring and storage are achieved.
f) Details of the environment in which the crane might be used during the period covered by the
scheme.
g) Identification of those parts of the crane requiring thorough examination and the probable
reasons for the deterioration, for example wear and corrosion.
h) Frequency of thorough examination for those identified parts which might include time, loading or
duty cycle limits and which might vary for different parts of the equipment.
i) Method of thorough examination of those identified parts that require thorough examination,
which might include the degree of dismantling required, any preparation to be carried out by the
user before the examination, NDT techniques, timed replacement, etc.
26 © SABS
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j) An indication of the resources required to carry out the inspection. This might include crane
inspector(s), workshop facilities, specialist NDT and metallurgical facilities, etc.
k) Any changes to the condition of the equipment, or to operational or environmental parameters

that would require a review of the scheme by the crane inspector. These may include damage to
the structure, change of use from general use to heavy-duty work, or moving from an inland
location to a marine environment.
l) The date of drawing up the scheme and the date at which any routine review is required.
F.5 The examination scheme shall determine whether all mechanisms function correctly and are
free from defects and whether the crane is safe for further use.
F.6 If it is not possible to comply with any of the requirements of the examination scheme, the
crane shall be subjected to specified periodic inspections.
© SABS 27
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Annex G
(normative)
Test procedure
G.1 Before commencing the test, the crane gantry and track in the test area shall be visually
inspected to determine their suitability to withstand the test loads.
G.2 At the start of the test, the crane shall be positioned over a supporting stanchion or column of
the gantry, where applicable, with the crab positioned as to minimize its influence on the crane
bridge deflection. With the crane in this position, a datum position of the crane main girders at the
point of maximum deflection shall be established.
G.3 The SWL shall be raised until each tooth of the train of gears has been subjected to the load.
Lower the load to 100 mm to 200 mm above the ground and hold the load in this position for 10 min
to ensure the load does not slip through the brake.
G.4 The crab shall be traversed to the point of maximum deflection and the deflection recorded.
NOTE If, owing to a crane’s specific design, this method of testing is not possible, follow the crane
manufacturer’s or crane inspector’s recommendations to perform this process.
G.5 The load shall be moved using the crane motions to ensure that all load-bearing elements are
subjected to the maximum load at least once.
G.6 The crane shall be operated at the maximum speed with the SWL and all motion electrical
limit devices, emergency stops and brakes shall be tested. The crane shall perform in accordance
with the information as specified by the original equipment manufacturer (OEM).
NOTE Emergency brakes or storm brakes (or both) may be excluded at the discretion of the crane inspector,
should it cause an unsafe situation.
G.7 The load shall be Increased to constitute an overload of not more than 110 % of the SWL and
test the functionality of the load-limiting device.
G.8 For cranes with two or more hoists, separate tests shall be carried out for each hoist. Where
the use of more than one hoist at a time is permitted, all tests, including the measurement of
deflection, shall be carried out with all the hoists loaded simultaneously.
G.9 Once the load has been removed, the hoist shall be moved to the datum position and ensure
the crane returned to the datum position.
28 © SABS
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Annex H
(informative)
Certificate No. …………….
Certificate of inspection/testing of overhead crane
1 Name and address of owner of crane

Location
2 Make of crane
3 Type of crane
4 Date of manufacture of crane
5 Identification or serial number
6 SWL (including auxiliary hoists)
7 Date of previous test of crane
8 Date of previous thorough inspection of crane
9 Type of inspection or test (e.g. 6 months(lifting
people), 12 months, examination scheme
approach, exceptional, major,
repairs/modifications)
10 Defects
11 Recommendations
12 Time scale for repair, renewal, alteration
I hereby certify that the overhead crane described in this Certificate was thoroughly inspected and tested on
……............................... and that the above particulars are correct.
The overhead crane is safe/unsafe for use.
The overhead crane should be inspected/tested before............................................(next date)
NAME (print)…………….................………….......….. Qualification……………...............…………………………….
Signature………………................………….......……..Date of Certificate……………….……......................………..
Name and address of entity by whom the person conducting the test and examination is employed.
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
Registration number : .............................................
© SABS 29
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Certificate of inspection (concluded)
Certificate No. …………….
Certificate of inspection/testing of overhead crane
I hereby certify that the overhead crane described in this certificate was thoroughly inspected and tested on
………............................... and that the above particulars are correct.
The overhead crane is safe/unsafe for use.
The overhead crane should be inspected/tested before............................................(next date)
NAME (print)…………….................………….......….. Qualification……………...............…………………………….
Signature………………................………….......……..Date of Certificate……………….……......................………..
Name and address of entity by whom the person conducting the test and examination is employed.
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
Registration number: .............................................
30 © SABS
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Annex I
(informative)
Non-destructive testing — Most common types
I.1 Magnetic particle examination

In this technique, a magnetic field is induced in the area under examination whilst the surface is
flooded with ferrous particles suspended in a liquid. Any cracks or defects cause a discontinuity in
the magnetic field, which in turn causes the ferrous particles to cluster over the defect, indicating its
presence by a dark line. This technique is only suitable for magnetic materials (most structural
steels and some stainless steels), and only detects surface defects and large defects just below the
material surface. Further guidance is given in ISO 9934, PD 6513 and EN 10228-1.
I.2 Dye penetrant

In this technique, the surface of the material is flooded with a liquid dye which penetrates into any
surface cracks or defects. After a specified period, the dye is cleaned off and the surface is sprayed
with an absorbent "developer" which draws the dye from any defects, indicating the presence of the
defect. The technique is often employed on non-ferrous materials such as aluminium alloys, but can
only locate surface defects. Further guidance is given in SANS 3452-1 and EN 10228-2.
I.3 Ultrasonic examination

In this technique, pulses of high-frequency sound waves are transmitted from the surface of the
material into its interior. Any defects or discontinuities cause the sound waves to be reflected back to
the surface where they can be detected and, by the measurement of the time delay from the time of
transmission, an estimate of the defect’s depth below the surface can be made. The technique can
be used for a wide range of materials, and detects both surface and subsurface defects. However, it
requires both a skilled operator and specialist equipment, and would normally be carried out by a
specialist firm. Further guidance is given in ISO 16823.
© SABS 31
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Bibliography
BS 7121-1, Code of practice for safe use of cranes – Part 1: General.
EN 10228-1, Non-destructive testing of steel forgings – Part 1: Magnetic particle inspection.
EN 10228-2, Non-destructive testing of steel forgings – Part 2: Penetrant testing.
ISO 9927-1, Cranes – Inspections – Part 1: General.
ISO 9934 (all parts), Non-destructive testing – Magnetic particle testing.
ISO 16823, Non-destructive testing – Ultrasonic testing – Transmission technique.
PD 6513, Magnetic particle flaw detection – A guide to the principles and practice of applying
magnetic particle flaw detection in accordance with BS 6072.
SANS 3452-1/ISO 3452-1, Non-destructive testing – Penetrant inspection – General principles.
SANS 4309/ISO 4309, Cranes – Wire ropes – Care, maintenance, installation, examination and
discard.
SANS 9712/ISO 9712, Non-destructive testing – Qualification and certification of personnel.
SANS 53411-6/EN 13411-6, Terminations for steel wire ropes – Safety – Part 6: Asymmetric wedge
socket.
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SOUTH AFRICAN NATIONAL STANDARD

The inspection and testing of overhead

Published by the South African Bureau of Standards

This page has been left blank intentionally

COPYRIGHT PROTECTED DOCUMENT

SABS – Standards Division

SABS Customer Services provide comprehensive standards-related information on national, regional

This document was approved for publication in March 2018.

This document supersedes SANS 10375:2006 (edition 1).

2 Normative reference .............................................................................................................. 3

5 Facilities, information, equipment and precautions ................................................................. 6

7 Major or structural repairs or modifications to load path ......................................................... 15

8 Non-destructive testing ........................................................................................................... 15

Annex A (normative) Inspection precautions .............................................................................. 18

Annex B (informative) Daily inspection checklist ........................................................................ 19

Annex C (informative) Frequent inspection checklist.................................................................. 20

Annex D (normative) Lifting of persons – Inspection and testing of cranes and

Annex E (informative) Verification of hooks ................................................................................ 25

Annex F (normative) Examination scheme approach ................................................................. 26

Annex G (normative) Test procedure ......................................................................................... 28

Annex H (informative) Certificate of inspection/testing of overhead crane ................................. 29

Annex I (informative) Non-destructive testing — Most common types ....................................... 31

This page is intentionally left blank

The inspection and testing of overhead cranes

EN 14502-1, Cranes – Equipment for lifting of persons – Part 1: Suspended baskets.

ISO 4306-1, Cranes – Vocabulary – Part 1: General.

SANS 687, Inspection and testing of non-fixed load-lifting attachments.

SANS 4310, Cranes – Test code and procedures.

SANS 12482-1/ISO 12482-1, Cranes condition monitoring – Part 1: General.

NOTE 2 This is applicable where the manufacturer seizes to exist.

NOTE NDT is also known as non-destructive examination (NDE).

5 Facilities, information, equipment and precautions

5.3.1 Measuring equipment

5.3.2 Test weights

The test weights shall be

a) weights of proven accuracy to within ± 1,0 %;

5.3.3 Precautions for inspection

6.1.8 The following inspections are applicable:

c) periodic thorough inspection;

d) examination scheme approach;

e) exceptional inspection; and

6.2 Daily inspections

6.3 Frequent inspections

6.4 Periodic thorough inspections

6.4.1.2 Work platforms shall comply with EN 14502-1.

6.4.1.7 Particular attention shall be given to the following:

b) unusual noise or temperature;

c) poor general condition, corrosion;

d) alignment of machinery, motor and gears, rails, wheels, shafts; and

e) load rope condition.

6.4.2 Checks and tests to be carried out

g) Examine the general appearance and condition of the crane.

2) bridge girders, and their mechanisms;

6) end stops and buffers;

6) long travel or cross travel wheels, as relevant;

The maximum allowable flange wear shall be 50 % of original thickness.