[Title 29 CFR 1910.179]
[Code of Federal Regulations (annual edition) - July 1, 2002 Edition]
[Title 29 - LABOR]
[Subtitle B - Regulations Relating to Labor (Continued)]
[Chapter Xvii - OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT]
[Part 1910 - OCCUPATIONAL SAFETY AND HEALTH STANDARDS]
[Subpart N - Materials Handling and Storage]
[Sec. 1910.179 - Overhead and gantry cranes.]
[From the U.S. Government Printing Office]


29LABOR52002-07-012002-07-01false1910.179Sec. 1910.179LABORRegulations Relating to Labor (Continued)OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION, DEPARTMENTOCCUPATIONAL SAFETY AND HEALTH STANDARDSMaterials Handling and Storage
Sec. 1910.179  Overhead and gantry cranes.

    (a) Definitions applicable to this section. (1) A crane is a machine 
for lifting and lowering a load and moving it horizontally, with the 
hoisting mechanism an integral part of the machine. Cranes whether fixed 
or mobile are driven manually or by power.
    (2) An automatic crane is a crane which when activated operates 
through a preset cycle or cycles.
    (3) A cab-operated crane is a crane controlled by an operator in a 
cab located on the bridge or trolley.
    (4) Cantilever gantry crane means a gantry or semigantry crane in 
which the bridge girders or trusses extend transversely beyond the crane 
runway on one or both sides.
    (5) Floor-operated crane means a crane which is pendant or 
nonconductive rope controlled by an operator on the floor or an 
independent platform.
    (6) Gantry crane means a crane similar to an overhead crane except 
that the bridge for carrying the trolley or trolleys is rigidly 
supported on two or more legs running on fixed rails or other runway.
    (7) Hot metal handling crane means an overhead crane used for 
transporting or pouring molten material.
    (8) Overhead crane means a crane with a movable bridge carrying a 
movable or fixed hoisting mechanism and traveling on an overhead fixed 
runway structure.
    (9) Power-operated crane means a crane whose mechanism is driven by 
electric, air, hydraulic, or internal combustion means.
    (10) A pulpit-operated crane is a crane operated from a fixed 
operator station not attached to the crane.
    (11) A remote-operated crane is a crane controlled by an operator 
not in a pulpit or in the cab attached to the crane, by any method other 
than pendant or rope control.

[[Page 557]]

    (12) A semigantry crane is a gantry crane with one end of the bridge 
rigidly supported on one or more legs that run on a fixed rail or 
runway, the other end of the bridge being supported by a truck running 
on an elevated rail or runway.
    (13) Storage bridge crane means a gantry type crane of long span 
usually used for bulk storage of material; the bridge girders or trusses 
are rigidly or nonrigidly supported on one or more legs. It may have one 
or more fixed or hinged cantilever ends.
    (14) Wall crane means a crane having a jib with or without trolley 
and supported from a side wall or line of columns of a building. It is a 
traveling type and operates on a runway attached to the side wall or 
columns.
    (15) Appointed means assigned specific responsibilities by the 
employer or the employer's representative.
    (16) ANSI means the American National Standards Institute.
    (17) An auxiliary hoist is a supplemental hoisting unit of lighter 
capacity and usually higher speed than provided for the main hoist.
    (18) A brake is a device used for retarding or stopping motion by 
friction or power means.
    (19) A drag brake is a brake which provides retarding force without 
external control.
    (20) A holding brake is a brake that automatically prevents motion 
when power is off.
    (21) Bridge means that part of a crane consisting of girders, 
trucks, end ties, footwalks, and drive mechanism which carries the 
trolley or trolleys.
    (22) Bridge travel means the crane movement in a direction parallel 
to the crane runway.
    (23) A bumper (buffer) is an energy absorbing device for reducing 
impact when a moving crane or trolley reaches the end of its permitted 
travel; or when two moving cranes or trolleys come in contact.
    (24) The cab is the operator's compartment on a crane.
    (25) Clearance means the distance from any part of the crane to a 
point of the nearest obstruction.
    (26) Collectors current are contacting devices for collecting 
current from runway or bridge conductors.
    (27) Conductors, bridge are the electrical conductors located along 
the bridge structure of a crane to provide power to the trolley.
    (28) Conductors, runway (main) are the electrical conductors located 
along a crane runway to provide power to the crane.
    (29) The control braking means is a method of controlling crane 
motor speed when in an overhauling condition.
    (30) Countertorque means a method of control by which the power to 
the motor is reversed to develop torque in the opposite direction.
    (31) Dynamic means a method of controlling crane motor speeds when 
in the overhauling condition to provide a retarding force.
    (32) Regenerative means a form of dynamic braking in which the 
electrical energy generated is fed back into the power system.
    (33) Mechanical means a method of control by friction.
    (34) Controller, spring return means a controller which when 
released will return automatically to a neutral position.
    (35) Designated means selected or assigned by the employer or the 
employer's representative as being qualified to perform specific duties.
    (36) A drift point means a point on a travel motion controller which 
releases the brake while the motor is not energized. This allows for 
coasting before the brake is set.
    (37) The drum is the cylindrical member around which the ropes are 
wound for raising or lowering the load.
    (38) An equalizer is a device which compensates for unequal length 
or stretch of a rope.
    (39) Exposed means capable of being contacted inadvertently. Applied 
to hazardous objects not adequately guarded or isolated.
    (40) Fail-safe means a provision designed to automatically stop or 
safely control any motion in which a malfunction occurs.
    (41) Footwalk means the walkway with handrail, attached to the 
bridge or trolley for access purposes.
    (42) A hoist is an apparatus which may be a part of a crane, 
exerting a force for lifting or lowering.

[[Page 558]]

    (43) Hoist chain means the load bearing chain in a hoist.
    Note: Chain properties do not conform to those shown in ANSI B30.9-
1971, Safety Code for Slings.
    (44) Hoist motion means that motion of a crane which raises and 
lowers a load.
    (45) Load means the total superimposed weight on the load block or 
hook.
    (46) The load block is the assembly of hook or shackle, swivel, 
bearing, sheaves, pins, and frame suspended by the hoisting rope.
    (47) Magnet means an electromagnetic device carried on a crane hook 
to pick up loads magnetically.
    (48) Main hoist means the hoist mechanism provided for lifting the 
maximum rated load.
    (49) A man trolley is a trolley having an operator's cab attached 
thereto.
    (50) Rated load means the maximum load for which a crane or 
individual hoist is designed and built by the manufacturer and shown on 
the equipment nameplate(s).
    (51) Rope refers to wire rope, unless otherwise specified.
    (52) Running sheave means a sheave which rotates as the load block 
is raised or lowered.
    (53) Runway means an assembly of rails, beams, girders, brackets, 
and framework on which the crane or trolley travels.
    (54) Side pull means that portion of the hoist pull acting 
horizontally when the hoist lines are not operated vertically.
    (55) Span means the horizontal distance center to center of runway 
rails.
    (56) Standby crane means a crane which is not in regular service but 
which is used occasionally or intermittently as required.
    (57) A stop is a device to limit travel of a trolley or crane 
bridge. This device normally is attached to a fixed structure and 
normally does not have energy absorbing ability.
    (58) A switch is a device for making, breaking, or for changing the 
connections in an electric circuit.
    (59) An emergency stop switch is a manually or automatically 
operated electric switch to cut off electric power independently of the 
regular operating controls.
    (60) A limit switch is a switch which is operated by some part or 
motion of a power-driven machine or equipment to alter the electric 
circuit associated with the machine or equipment.
    (61) A main switch is a switch controlling the entire power supply 
to the crane.
    (62) A master switch is a switch which dominates the operation of 
contactors, relays, or other remotely operated devices.
    (63) The trolley is the unit which travels on the bridge rails and 
carries the hoisting mechanism.
    (64) Trolley travel means the trolley movement at right angles to 
the crane runway.
    (65) Truck means the unit consisting of a frame, wheels, bearings, 
and axles which supports the bridge girders or trolleys.
    (b) General requirements--(1) Application. This section applies to 
overhead and gantry cranes, including semigantry, cantilever gantry, 
wall cranes, storage bridge cranes, and others having the same 
fundamental characteristics. These cranes are grouped because they all 
have trolleys and similar travel characteristics.
    (2) New and existing equipment. All new overhead and gantry cranes 
constructed and installed on or after August 31, 1971, shall meet the 
design specifications of the American National Standard Safety Code for 
Overhead and Gantry Cranes, ANSI B30.2.0-1967, which is incorporated by 
reference as specified in Sec. 1910.6.
    (3) Modifications. Cranes may be modified and rerated provided such 
modifications and the supporting structure are checked thoroughly for 
the new rated load by a qualified engineer or the equipment 
manufacturer. The crane shall be tested in accordance with paragraph 
(k)(2) of this section. New rated load shall be displayed in accordance 
with subparagraph (5) of this paragraph.
    (4) Wind indicators and rail clamps. Outdoor storage bridges shall 
be provided with automatic rail clamps. A wind-indicating device shall 
be provided which will give a visible or audible alarm to the bridge 
operator at a predetermined wind velocity. If the clamps act on the rail 
heads, any beads

[[Page 559]]

or weld flash on the rail heads shall be ground off.
    (5) Rated load marking. The rated load of the crane shall be plainly 
marked on each side of the crane, and if the crane has more than one 
hoisting unit, each hoist shall have its rated load marked on it or its 
load block and this marking shall be clearly legible from the ground or 
floor.
    (6) Clearance from obstruction. (i) Minimum clearance of 3 inches 
overhead and 2 inches laterally shall be provided and maintained between 
crane and obstructions in conformity with Crane Manufacturers 
Association of America, Inc., Specification No. 61, which is 
incorporated by reference as specified in Sec. 1910.6 (formerly the 
Electric Overhead Crane Institute, Inc).
    (ii) Where passageways or walkways are provided obstructions shall 
not be placed so that safety of personnel will be jeopardized by 
movements of the crane.
    (7) Clearance between parallel cranes. If the runways of two cranes 
are parallel, and there are no intervening walls or structure, there 
shall be adequate clearance provided and maintained between the two 
bridges.
    (8) Designated personnel--Only designated personnel shall be 
permitted to operate a crane covered by this section.
    (c) Cabs--(1) Cab location. (i) The general arrangement of the cab 
and the location of control and protective equipment shall be such that 
all operating handles are within convenient reach of the operator when 
facing the area to be served by the load hook, or while facing the 
direction of travel of the cab. The arrangement shall allow the operator 
a full view of the load hook in all positions.
    (ii) The cab shall be located to afford a minimum of 3 inches 
clearance from all fixed structures within its area of possible 
movement.
    (2) Access to crane. Access to the cab and/or bridge walkway shall 
be by a conveniently placed fixed ladder, stairs, or platform requiring 
no step over any gap exceeding 12 inches. Fixed ladders shall be in 
conformance with the American National Standard Safety Code for Fixed 
Ladders, ANSI A14.3-1956, which is incorporated by reference as 
specified in Sec. 1910.6.
    (3) Fire extinguisher. Carbon tetrachloride extinguishers shall not 
be used.
    (4) Lighting. Light in the cab shall be sufficient to enable the 
operator to see clearly enough to perform his work.
    (d) Footwalks and ladders--(1) Location of footwalks. (i) If 
sufficient headroom is available on cab-operated cranes, a footwalk 
shall be provided on the drive side along the entire length of the 
bridge of all cranes having the trolley running on the top of the 
girders.
    (ii) Where footwalks are located in no case shall less than 48 
inches of headroom be provided.
    (2) Construction of footwalks. (i) Footwalks shall be of rigid 
construction and designed to sustain a distributed load of at least 50 
pounds per square foot.
    (ii) Footwalks shall have a walking surface of antislip type.
    Note: Wood will meet this requirement.
    (iii) [Reserved]
    (iv) The inner edge shall extend at least to the line of the outside 
edge of the lower cover plate or flange of the girder.
    (3) Toeboards and handrails for footwalks. Toeboards and handrails 
shall be in compliance with section 1910.23 of this part.
    (4) Ladders and stairways. (i) Gantry cranes shall be provided with 
ladders or stairways extending from the ground to the footwalk or cab 
platform.
    (ii) Stairways shall be equipped with rigid and substantial metal 
handrails. Walking surfaces shall be of an antislip type.
    (iii) Ladders shall be permanently and securely fastened in place 
and shall be constructed in compliance with Sec. 1910.27.
    (e) Stops, bumpers, rail sweeps, and guards--(1) Trolley stops. (i) 
Stops shall be provided at the limits of travel of the trolley.
    (ii) Stops shall be fastened to resist forces applied when 
contacted.
    (iii) A stop engaging the tread of the wheel shall be of a height at 
least equal to the radius of the wheel.
    (2) Bridge bumpers--(i) A crane shall be provided with bumpers or 
other automatic means providing equivalent effect, unless the crane 
travels at a

[[Page 560]]

slow rate of speed and has a faster deceleration rate due to the use of 
sleeve bearings, or is not operated near the ends of bridge and trolley 
travel, or is restricted to a limited distance by the nature of the 
crane operation and there is no hazard of striking any object in this 
limited distance, or is used in similar operating conditions. The 
bumpers shall be capable of stopping the crane (not including the lifted 
load) at an average rate of deceleration not to exceed 3 ft/s/s when 
traveling in either direction at 20 percent of the rated load speed.
    (a) The bumpers shall have sufficient energy absorbing capacity to 
stop the crane when traveling at a speed of at least 40 percent of rated 
load speed.
    (b) The bumper shall be so mounted that there is no direct shear on 
bolts.
    (ii) Bumpers shall be so designed and installed as to minimize parts 
falling from the crane in case of breakage.
    (3) Trolley bumpers--(i) A trolley shall be provided with bumpers or 
other automatic means of equivalent effect, unless the trolley travels 
at a slow rate of speed, or is not operated near the ends of bridge and 
trolley travel, or is restricted to a limited distance of the runway and 
there is no hazard of striking any object in this limited distance, or 
is used in similar operating conditions. The bumpers shall be capable of 
stopping the trolley (not including the lifted load) at an average rate 
of deceleration not to exceed 4.7 ft/s/s when traveling in either 
direction at one-third of the rated load speed.
    (ii) When more than one trolley is operated on the same bridge, each 
shall be equipped with bumpers or equivalent on their adjacent ends.
    (iii) Bumpers or equivalent shall be designed and installed to 
minimize parts falling from the trolley in case of age.
    (4) Rail sweeps. Bridge trucks shall be equipped with sweeps which 
extend below the top of the rail and project in front of the truck 
wheels.
    (5) Guards for hoisting ropes. (i) If hoisting ropes run near enough 
to other parts to make fouling or chafing possible, guards shall be 
installed to prevent this condition.
    (ii) A guard shall be provided to prevent contact between bridge 
conductors and hoisting ropes if they could come into contact.
    (6) Guards for moving parts. (i) Exposed moving parts such as gears, 
set screws, projecting keys, chains, chain sprockets, and reciprocating 
components which might constitute a hazard under normal operating 
conditions shall be guarded.
    (ii) Guards shall be securely fastened.
    (iii) Each guard shall be capable of supporting without permanent 
distortion the weight of a 200-pound person unless the guard is located 
where it is impossible for a person to step on it.
    (f) Brakes--(1) Brakes for hoists. (i) Each independent hoisting 
unit of a crane shall be equipped with at least one self-setting brake, 
hereafter referred to as a holding brake, applied directly to the motor 
shaft or some part of the gear train.
    (ii) Each independent hoisting unit of a crane, except worm-geared 
hoists, the angle of whose worm is such as to prevent the load from 
accelerating in the lowering direction shall, in addition to a holding 
brake, be equipped with control braking means to prevent overspeeding.
    (2) Holding brakes. (i) Holding brakes for hoist motors shall have 
not less than the following percentage of the full load hoisting torque 
at the point where the brake is applied.
    (a) 125 percent when used with a control braking means other than 
mechanical.
    (b) 100 percent when used in conjunction with a mechanical control 
braking means.
    (c) 100 percent each if two holding brakes are provided.
    (ii) Holding brakes on hoists shall have ample thermal capacity for 
the frequency of operation required by the service.
    (iii) Holding brakes on hoists shall be applied automatically when 
power is removed.
    (iv) Where necessary holding brakes shall be provided with 
adjustment means to compensate for wear.
    (v) The wearing surface of all holding-brake drums or discs shall be 
smooth.
    (vi) Each independent hoisting unit of a crane handling hot metal 
and having power control braking means shall

[[Page 561]]

be equipped with at least two holding brakes.
    (3) Control braking means. (i) A power control braking means such as 
regenerative, dynamic or countertorque braking, or a mechanically 
controlled braking means shall be capable of maintaining safe lowering 
speeds of rated loads.
    (ii) The control braking means shall have ample thermal capacity for 
the frequency of operation required by service.
    (4) Brakes for trolleys and bridges. (i) Foot-operated brakes shall 
not require an applied force of more than 70 pounds to develop 
manufacturer's rated brake torque.
    (ii) Brakes may be applied by mechanical, electrical, pneumatic, 
hydraulic, or gravity means.
    (iii) Where necessary brakes shall be provided with adjustment means 
to compensate for wear.
    (iv) The wearing surface of all brakedrums or discs shall be smooth.
    (v) All foot-brake pedals shall be constructed so that the 
operator's foot will not easily slip off the pedal.
    (vi) Foot-operated brakes shall be equipped with automatic means for 
positive release when pressure is released from the pedal.
    (vii) Brakes for stopping the motion of the trolley or bridge shall 
be of sufficient size to stop the trolley or bridge within a distance in 
feet equal to 10 percent of full load speed in feet per minute when 
traveling at full speed with full load.
    (viii) If holding brakes are provided on the bridge or trolleys, 
they shall not prohibit the use of a drift point in the control circuit.
    (ix) Brakes on trolleys and bridges shall have ample thermal 
capacity for the frequency of operation required by the service to 
prevent impairment of functions from overheating.
    (5) Application of trolley brakes. (i) On cab-operated cranes with 
cab on trolley, a trolley brake shall be required as specified under 
paragraph (f)(4) of this section.
    (ii) A drag brake may be applied to hold the trolley in a desired 
position on the bridge and to eliminate creep with the power off.
    (6) Application of bridge brakes. (i) On cab-operated cranes with 
cab on bridge, a bridge brake is required as specified under paragraph 
(f)(4) of this section.
    (ii) On cab-operated cranes with cab on trolley, a bridge brake of 
the holding type shall be required.
    (iii) On all floor, remote and pulpit-operated crane bridge drives, 
a brake of noncoasting mechanical drive shall be provided.
    (g) Electric equipment--(1) General. (i) Wiring and equipment shall 
comply with subpart S of this part.
    (ii) The control circuit voltage shall not exceed 600 volts for a.c. 
or d.c. current.
    (iii) The voltage at pendant push-buttons shall not exceed 150 volts 
for a.c. and 300 volts for d.c.
    (iv) Where multiple conductor cable is used with a suspended 
pushbutton station, the station must be supported in some satisfactory 
manner that will protect the electrical conductors against strain.
    (v) Pendant control boxes shall be constructed to prevent electrical 
shock and shall be clearly marked for identification of functions.
    (2) Equipment. (i) Electrical equipment shall be so located or 
enclosed that live parts will not be exposed to accidental contact under 
normal operating conditions.
    (ii) Electric equipment shall be protected from dirt, grease, oil, 
and moisture.
    (iii) Guards for live parts shall be substantial and so located that 
they cannot be accidently deformed so as to make contact with the live 
parts.
    (3) Controllers. (i) Cranes not equipped with spring-return 
controllers or momentary contact pushbuttons shall be provided with a 
device which will disconnect all motors from the line on failure of 
power and will not permit any motor to be restarted until the controller 
handle is brought to the ``off'' position, or a reset switch or button 
is operated.
    (ii) Lever operated controllers shall be provided with a notch or 
latch which in the ``off'' position prevents the handle from being 
inadvertently moved to the ``on'' position. An ``off'' detent or spring 
return arrangement is acceptable.

[[Page 562]]

    (iii) The controller operating handle shall be located within 
convenient reach of the operator.
    (iv) As far as practicable, the movement of each controller handle 
shall be in the same general directions as the resultant movements of 
the load.
    (v) The control for the bridge and trolley travel shall be so 
located that the operator can readily face the direction of travel.
    (vi) For floor-operated cranes, the controller or controllers if 
rope operated, shall automatically return to the ``off'' position when 
released by the operator.
    (vii) Pushbuttons in pendant stations shall return to the ``off'' 
position when pressure is released by the crane operator.
    (viii) Automatic cranes shall be so designed that all motions shall 
fail-safe if any malfunction of operation occurs.
    (ix) Remote-operated cranes shall function so that if the control 
signal for any crane motion becomes ineffective the crane motion shall 
stop.
    (4) Resistors. (i) Enclosures for resistors shall have openings to 
provide adequate ventilation, and shall be installed to prevent the 
accumulation of combustible matter too near to hot parts.
    (ii) Resistor units shall be supported so as to be as free as 
possible from vibration.
    (iii) Provision shall be made to prevent broken parts or molten 
metal falling upon the operator or from the crane.
    (5) Switches. (i) The power supply to the runway conductors shall be 
controlled by a switch or circuit breaker located on a fixed structure, 
accessible from the floor, and arranged to be locked in the open 
position.
    (ii) On cab-operated cranes a switch or circuit breaker of the 
enclosed type, with provision for locking in the open position, shall be 
provided in the leads from the runway conductors. A means of opening 
this switch or circuit breaker shall be located within easy reach of the 
operator.
    (iii) On floor-operated cranes, a switch or circuit breaker of the 
enclosed type, with provision for locking in the open position, shall be 
provided in the leads from the runway conductors. This disconnect shall 
be mounted on the bridge or footwalk near the runway collectors. One of 
the following types of floor-operated disconnects shall be provided:
    (a) Nonconductive rope attached to the main disconnect switch.
    (b) An undervoltage trip for the main circuit breaker operated by an 
emergency stop button in the pendant pushbutton in the pendant 
pushbutton station.
    (c) A main line contactor operated by a switch or pushbutton in the 
pendant pushbutton station.
    (iv) The hoisting motion of all electric traveling cranes shall be 
provided with an overtravel limit switch in the hoisting direction.
    (v) All cranes using a lifting magnet shall have a magnet circuit 
switch of the enclosed type with provision for locking in the open 
position. Means for discharging the inductive load of the magnet shall 
be provided.
    (6) Runway conductors. Conductors of the open type mounted on the 
crane runway beams or overhead shall be so located or so guarded that 
persons entering or leaving the cab or crane footwalk normally could not 
come into contact with them.
    (7) Extension lamps. If a service receptacle is provided in the cab 
or on the bridge of cab-operated cranes, it shall be a grounded three-
prong type permanent receptacle, not exceeding 300 volts.
    (h) Hoisting equipment--(1) Sheaves. (i) Sheave grooves shall be 
smooth and free from surface defects which could cause rope damage.
    (ii) Sheaves carrying ropes which can be momentarily unloaded shall 
be provided with close-fitting guards or other suitable devices to guide 
the rope back into the groove when the load is applied again.
    (iii) The sheaves in the bottom block shall be equipped with close-
fitting guards that will prevent ropes from becoming fouled when the 
block is lying on the ground with ropes loose.
    (iv) Pockets and flanges of sheaves used with hoist chains shall be 
of such dimensions that the chain does not catch or bind during 
operation.

[[Page 563]]

    (v) All running sheaves shall be equipped with means for 
lubrication. Permanently lubricated, sealed and/or shielded bearings 
meet this requirement.
    (2) Ropes. (i) In using hoisting ropes, the crane manufacturer's 
recommendation shall be followed. The rated load divided by the number 
of parts of rope shall not exceed 20 percent of the nominal breaking 
strength of the rope.
    (ii) Socketing shall be done in the manner specified by the 
manufacturer of the assembly.
    (iii) Rope shall be secured to the drum as follows:
    (a) No less than two wraps of rope shall remain on the drum when the 
hook is in its extreme low position.
    (b) Rope end shall be anchored by a clamp securely attached to the 
drum, or by a socket arrangement approved by the crane or rope 
manufacturer.
    (iv) Eye splices. [Reserved]
    (v) Rope clips attached with U-bolts shall have the U-bolts on the 
dead or short end of the rope. Spacing and number of all types of clips 
shall be in accordance with the clip manufacturer's recommendation. 
Clips shall be drop-forged steel in all sizes manufactured commercially. 
When a newly installed rope has been in operation for an hour, all nuts 
on the clip bolts shall be retightened.
    (vi) Swaged or compressed fittings shall be applied as recommended 
by the rope or crane manufacturer.
    (vii) Wherever exposed to temperatures, at which fiber cores would 
be damaged, rope having an independent wirerope or wire-strand core, or 
other temperature-damage resistant core shall be used.
    (viii) Replacement rope shall be the same size, grade, and 
construction as the original rope furnished by the crane manufacturer, 
unless otherwise recommended by a wire rope manufacturer due to actual 
working condition requirements.
    (3) Equalizers. If a load is supported by more than one part of 
rope, the tension in the parts shall be equalized.
    (4) Hooks. Hooks shall meet the manufacturer's recommendations and 
shall not be overloaded.
    (i) Warning device. Except for floor-operated cranes a gong or other 
effective warning signal shall be provided for each crane equipped with 
a power traveling mechanism.
    (j) Inspection--(1) Inspection classification. (i) Initial 
inspection. Prior to initial use all new and altered cranes shall be 
inspected to insure compliance with the provisions of this section.
    (ii) Inspection procedure for cranes in regular service is divided 
into two general classifications based upon the intervals at which 
inspection should be performed. The intervals in turn are dependent upon 
the nature of the critical components of the crane and the degree of 
their exposure to wear, deterioration, or malfunction. The two general 
classifications are herein designated as ``frequent'' and ``periodic'' 
with respective intervals between inspections as defined below:
    (a) Frequent inspection--Daily to monthly intervals.
    (b) Periodic inspection--1 to 12- month intervals.
    (2) Frequent inspection. The following items shall be inspected for 
defects at intervals as defined in paragraph (j)(1)(ii) of this section 
or as specifically indicated, including observation during operation for 
any defects which might appear between regular inspections. All 
deficiencies such as listed shall be carefully examined and 
determination made as to whether they constitute a safety hazard:
    (i) All functional operating mechanisms for maladjustment 
interfering with proper operation. Daily.
    (ii) Deterioration or leakage in lines, tanks, valves, drain pumps, 
and other parts of air or hydraulic systems. Daily.
    (iii) Hooks with deformation or cracks. Visual inspection daily; 
monthly inspection with a certification record which includes the date 
of inspection, the signature of the person who performed the inspection 
and the serial number, or other identifier, of the hook inspected. For 
hooks with cracks or having more than 15 percent in excess of normal 
throat opening or more than 10 deg. twist from the plane of the unbent 
hook refer to paragraph (l)(3)(iii)(a) of this section.
    (iv) Hoist chains, including end connections, for excessive wear, 
twist, distorted links interfering with proper

[[Page 564]]

function, or stretch beyond manufacturer's recommendations. Visual 
inspection daily; monthly inspection with a certification record which 
includes the date of inspection, the signature of the person who 
performed the inspection and an identifier of the chain which was 
inspected.
    (v) [Reserved]
    (vi) All functional operating mechanisms for excessive wear of 
components.
    (vii) Rope reeving for noncompliance with manufacturer's 
recommendations.
    (3) Periodic inspection. Complete inspections of the crane shall be 
performed at intervals as generally defined in paragraph (j)(1)(ii)(b) 
of this section, depending upon its activity, severity of service, and 
environment, or as specifically indicated below. These inspections shall 
include the requirements of paragraph (j)(2) of this section and in 
addition, the following items. Any deficiencies such as listed shall be 
carefully examined and determination made as to whether they constitute 
a safety hazard:
    (i) Deformed, cracked, or corroded members.
    (ii) Loose bolts or rivets.
    (iii) Cracked or worn sheaves and drums.
    (iv) Worn, cracked or distorted parts such as pins, bearings, 
shafts, gears, rollers, locking and clamping devices.
    (v) Excessive wear on brake system parts, linings, pawls, and 
ratchets.
    (vi) Load, wind, and other indicators over their full range, for any 
significant inaccuracies.
    (vii) Gasoline, diesel, electric, or other powerplants for improper 
performance or noncompliance with applicable safety requirements.
    (viii) Excessive wear of chain drive sprockets and excessive chain 
stretch.
    (ix) [Reserved]
    (x) Electrical apparatus, for signs of pitting or any deterioration 
of controller contactors, limit switches and pushbutton stations.
    (4) Cranes not in regular use. (i) A crane which has been idle for a 
period of 1 month or more, but less than 6 months, shall be given an 
inspection conforming with requirements of paragraph (j)(2) of this 
section and paragraph (m)(2) of this section before placing in service.
    (ii) A crane which has been idle for a period of over 6 months shall 
be given a complete inspection conforming with requirements of 
paragraphs (j) (2) and (3) of this section and paragraph (m)(2) of this 
section before placing in service.
    (iii) Standby cranes shall be inspected at least semi-annually in 
accordance with requirements of paragraph (j)(2) of this section and 
paragraph (m)(2) of this section.
    (k) Testing--(1) Operational tests. (i) Prior to initial use all new 
and altered cranes shall be tested to insure compliance with this 
section including the following functions:
    (a) Hoisting and lowering.
    (b) Trolley travel.
    (c) Bridge travel.
    (d) Limit switches, locking and safety devices.
    (ii) The trip setting of hoist limit switches shall be determined by 
tests with an empty hook traveling in increasing speeds up to the 
maximum speed. The actuating mechanism of the limit switch shall be 
located so that it will trip the switch, under all conditions, in 
sufficient time to prevent contact of the hook or hook block with any 
part of the trolley.
    (2) Rated load test. Test loads shall not be more than 125 percent 
of the rated load unless otherwise recommended by the manufacturer. The 
test reports shall be placed on file where readily available to 
appointed personnel.
    (l) Maintenance--(1) Preventive maintenance. A preventive 
maintenance program based on the crane manufacturer's recommendations 
shall be established.
    (2) Maintenance procedure. (i) Before adjustments and repairs are 
started on a crane the following precautions shall be taken:
    (a) The crane to be repaired shall be run to a location where it 
will cause the least interference with other cranes and operations in 
the area.
    (b) All controllers shall be at the off position.
    (c) The main or emergency switch shall be open and locked in the 
open position.

[[Page 565]]

    (d) Warning or ``out of order'' signs shall be placed on the crane, 
also on the floor beneath or on the hook where visible from the floor.
    (e) Where other cranes are in operation on the same runway, rail 
stops or other suitable means shall be provided to prevent interference 
with the idle crane.
    (ii) After adjustments and repairs have been made the crane shall 
not be operated until all guards have been reinstalled, safety devices 
reactivated and maintenance equipment removed.
    (3) Adjustments and repairs. (i) Any unsafe conditions disclosed by 
the inspection requirements of paragraph (j) of this section shall be 
corrected before operation of the crane is resumed. Adjustments and 
repairs shall be done only by designated personnel.
    (ii) Adjustments shall be maintained to assure correct functioning 
of components. The following are examples:
    (a) All functional operating mechanisms.
    (b) Limit switches.
    (c) Control systems.
    (d) Brakes.
    (e) Power plants.
    (iii) Repairs or replacements shall be provided promptly as needed 
for safe operation. The following are examples:
    (a) Crane hooks showing defects described in paragraph (j)(2)(iii) 
of this section shall be discarded. Repairs by welding or reshaping are 
not generally recommended. If such repairs are attempted they shall only 
be done under competent supervision and the hook shall be tested to the 
load requirements of paragraph (k)(2) of this section before further 
use.
    (b) Load attachment chains and rope slings showing defects described 
in paragraph (j)(2) (iv) and (v) of this section respectively.
    (c) All critical parts which are cracked, broken, bent, or 
excessively worn.
    (d) Pendant control stations shall be kept clean and function labels 
kept legible.
    (m) Rope inspection--(1) Running ropes. A thorough inspection of all 
ropes shall be made at least once a month and a certification record 
which includes the date of inspection, the signature of the person who 
performed the inspection and an identifier for the ropes which were 
inspected shall be kept on file where readily available to appointed 
personnel. Any deterioration, resulting in appreciable loss of original 
strength, shall be carefully observed and determination made as to 
whether further use of the rope would constitute a safety hazard. Some 
of the conditions that could result in an appreciable loss of strength 
are the following:
    (i) Reduction of rope diameter below nominal diameter due to loss of 
core support, internal or external corrosion, or wear of outside wires.
    (ii) A number of broken outside wires and the degree of distribution 
or concentration of such broken wires.
    (iii) Worn outside wires.
    (iv) Corroded or broken wires at end connections.
    (v) Corroded, cracked, bent, worn, or improperly applied end 
connections.
    (vi) Severe kinking, crushing, cutting, or unstranding.
    (2) Other ropes. All rope which has been idle for a period of a 
month or more due to shutdown or storage of a crane on which it is 
installed shall be given a thorough inspection before it is used. This 
inspection shall be for all types of deterioration and shall be 
performed by an appointed person whose approval shall be required for 
further use of the rope. A certification record shall be available for 
inspection which includes the date of inspection, the signature of the 
person who performed the inspection and an identifier for the rope which 
was inspected.
    (n) Handling the load--(1) Size of load. The crane shall not be 
loaded beyond its rated load except for test purposes as provided in 
paragraph (k) of this section.
    (2) Attaching the load. (i) The hoist chain or hoist rope shall be 
free from kinks or twists and shall not be wrapped around the load.
    (ii) The load shall be attached to the load block hook by means of 
slings or other approved devices.
    (iii) Care shall be taken to make certain that the sling clears all 
obstacles.
    (3) Moving the load. (i) The load shall be well secured and properly 
balanced in the sling or lifting device before it is lifted more than a 
few inches.

[[Page 566]]

    (ii) Before starting to hoist the following conditions shall be 
noted:
    (a) Hoist rope shall not be kinked.
    (b) Multiple part lines shall not be twisted around each other.
    (c) The hook shall be brought over the load in such a manner as to 
prevent swinging.
    (iii) During hoisting care shall be taken that:
    (a) There is no sudden acceleration or deceleration of the moving 
load.
    (b) The load does not contact any obstructions.
    (iv) Cranes shall not be used for side pulls except when 
specifically authorized by a responsible person who has determined that 
the stability of the crane is not thereby endangered and that various 
parts of the crane will not be overstressed.
    (v) While any employee is on the load or hook, there shall be no 
hoisting, lowering, or traveling.
    (vi) The employer shall require that the operator avoid carrying 
loads over people.
    (vii) The operator shall test the brakes each time a load 
approaching the rated load is handled. The brakes shall be tested by 
raising the load a few inches and applying the brakes.
    (viii) The load shall not be lowered below the point where less than 
two full wraps of rope remain on the hoisting drum.
    (ix) When two or more cranes are used to lift a load one qualified 
responsible person shall be in charge of the operation. He shall analyze 
the operation and instruct all personnel involved in the proper 
positioning, rigging of the load, and the movements to be made.
    (x) The employer shall insure that the operator does not leave his 
position at the controls while the load is suspended.
    (xi) When starting the bridge and when the load or hook approaches 
near or over personnel, the warning signal shall be sounded.
    (4) Hoist limit switch. (i) At the beginning of each operator's 
shift, the upper limit switch of each hoist shall be tried out under no 
load. Extreme care shall be exercised; the block shall be ``inched'' 
into the limit or run in at slow speed. If the switch does not operate 
properly, the appointed person shall be immediately notified.
    (ii) The hoist limit switch which controls the upper limit of travel 
of the load block shall never be used as an operating control.
    (o) Other requirements, general--(1) Ladders. (i) The employer shall 
insure that hands are free from encumbrances while personnel are using 
ladders.
    (ii) Articles which are too large to be carried in pockets or belts 
shall be lifted and lowered by hand line.
    (2) Cabs. (i) Necessary clothing and personal belongings shall be 
stored in such a manner as not to interfere with access or operation.
    (ii) Tools, oil cans, waste, extra fuses, and other necessary 
articles shall be stored in the tool box, and shall not be permitted to 
lie loose in or about the cab.
    (3) Fire extinguishers. The employer shall insure that operators are 
familiar with the operation and care of fire extinguishers provided.

[39 FR 23502, June 27, 1974, as amended at 40 FR 27400, June 27, 1975; 
49 FR 5322, Feb. 10, 1984; 51 FR 34560, Sept. 29, 1986; 55 FR 32015, 
Aug. 6, 1990; 61 FR 9239, Mar. 7, 1996]