During a crane inspection, the mechanical components, electrical parts, and the control system of the crane are thoroughly inspected. This includes lifting elements, brakes, bearings, cables, switch cabinets, and emergency stop provisions. In addition, a practical load test is carried out to confirm that the crane operates safely and in accordance with the applicable standards.
A crane inspection is mandatory for virtually every industrial lifting system in the Netherlands and Belgium. The inspection not only protects the safety of employees, but is also a legal requirement arising from European machinery directives and national occupational health and safety legislation. Below we answer the most frequently asked questions about the inspection of crane systems.
How often must a crane inspection be carried out?
A crane inspection must be carried out at least once a year. This applies to virtually all types of crane systems, including overhead travelling cranes, gantry cranes, and jib cranes. The annual crane inspection is a legal obligation arising from the European Machinery Directive and the Dutch Working Conditions Decree.
In addition to the annual inspection, interim inspections may be necessary. This is the case after a serious incident, after major repairs, or when the crane has been out of service for an extended period. A new inspection is also mandatory when the maximum load is changed or when modifications are made to the structure. The more intensively a crane system is used, the more important it is to align the inspection frequency accordingly, if necessary in consultation with the inspection body.
Which mechanical components are inspected during a crane inspection?
During the mechanical inspection of a crane, all load-bearing and moving parts of the system are assessed for wear, damage, and correct functioning. This forms the core of every inspection, as mechanical failure directly leads to safety risks.
The inspector checks, among other things, the following mechanical components:
- Lifting elements: lifting hooks, lifting blocks, and attachment points are checked for cracks, deformation, and wear
- Steel cables and chains: checked for wire breaks, kinks, corrosion, and excessive elongation
- Brakes: operation and wear of the brakes on the hoisting mechanism and travel movements
- Bearings and shafts: assessed for play, wear, and lubrication
- Runway and crab: rails, wheels, and connections are inspected for damage and alignment
- Supporting structure: the main girders, end beams, and connections are visually assessed for cracks, corrosion, or deformation
For older crane systems, the supporting structure deserves extra attention. Fatigue cracks in welded joints are not always visible to the naked eye, which is why an experienced inspector uses additional techniques such as visual inspection at critical points.
Which electrical and control components are inspected?
During a crane inspection, all electrical installations and control systems are also inspected. This includes the switch cabinet, wiring, contacts, protective devices, and the operating equipment. An electrical defect can lead to uncontrolled movements or fire, making this part of the inspection equally important as the mechanical inspection.
Specifically, the following electrical and control components are assessed:
- Emergency stop provisions: operation and accessibility of all emergency stop buttons
- Limit switches: check for correct setting and reliable operation at extreme positions
- Overload protection: operation of the load limiter that activates when the maximum lifting capacity is exceeded
- Wiring and cable ducts: visual check for damage, wear, and correct fastening
- Control panel and pendant: buttons, displays, and safety markings are checked for legibility and function
- Earthing and insulation resistance: electrical safety measurements to rule out short-circuit risks
What does the practical load test during an inspection involve?
The load test is a practical test in which the crane is loaded with a test weight that exceeds the nominal lifting capacity, typically 110 percent of the maximum working load. During this test, it is assessed whether the crane can safely handle the load and whether all safety devices respond correctly.
The load test proceeds step by step. First, the crane is loaded to its nominal capacity to check basic operation. Then the test load is applied and all movements are performed: hoisting, travelling, and slewing. The inspector pays attention to deflection of the structure, the behaviour of the brakes when the load is released, and the operation of the load limiter.
After the test, the structure and connections are visually inspected again for any deformations or new damage that occurred under load. The load test provides a realistic picture of how the crane system performs under actual conditions and is therefore an indispensable part of the annual crane inspection.
What happens if a crane fails the inspection?
If a crane fails the inspection, the system may no longer be used until the identified defects have been remedied. The inspection body records the shortcomings in an inspection report and indicates which remedial work is necessary before the crane can be put back into service.
Depending on the severity of the defects, various outcomes are possible. Minor shortcomings, such as a worn cable or a defective switch, can often be repaired quickly, after which a re-inspection takes place. In the case of more serious defects, such as cracks in the supporting structure or a failing overload protection, the crane is immediately taken out of service until a thorough repair has been carried out and approved.
Ignoring a failed inspection is not only dangerous, but also legally risky. In the event of an incident involving a rejected crane, the employer can be held liable for injury or damage. It is therefore essential to have identified defects repaired quickly and professionally.
Who is authorised to carry out an official crane inspection?
An official crane inspection may only be carried out by an accredited and qualified inspection body or a certified inspection company. In the Netherlands, inspecting bodies must meet the requirements arising from European standards and the Working Conditions Decree. An arbitrary technician or internal employee is not authorised to carry out a legally valid inspection.
The inspector must have demonstrable knowledge of the applicable standards, such as the NEN-EN 13001 series for crane calculations and NEN-EN 15011 for overhead travelling cranes. In addition, independence is a requirement: the inspecting party may not have a direct commercial interest in the outcome of the inspection.
Some companies choose to combine the inspection with regular maintenance. Although this is practical, it is important that the inspecting and maintaining parties have clearly separated responsibilities, so that the objectivity of the inspection is guaranteed.
How BKRS helps with the inspection of your crane system
As an accredited inspection company, BKRS manages the complete inspection process for your crane system, from the annual inspection to the load test and any necessary maintenance. You deal with a single point of contact who handles all coordination, planning, and communication on your behalf.
What we can do for you:
- Carrying out the annual crane inspection by certified inspectors
- Complete mechanical and electrical inspection of your crane system
- Practical load test in accordance with the applicable standards
- Clear inspection report with findings and recommendations
- Rapid repair of identified defects by our own structural and electrical department
- Planned crane maintenance to stay ahead of inspection issues
With more than forty years of experience in building, maintaining, and inspecting complex crane systems, we know exactly where the risks lie and how to keep your installation optimally safe. Would you like your crane inspection carried out by a reliable partner? Contact us and we will schedule the inspection at a time that suits your business operations.
Frequently Asked Questions
How long does a crane inspection take on average?
The duration of a crane inspection depends on the type and complexity of the crane system. For a standard overhead travelling crane, you should allow half a day to a full day, including the load test. Larger or more complex systems may take more time.
What do I as a company need to prepare before the inspection?
Make sure the crane is easily accessible, that previous inspection reports and maintenance documentation are available, and that a responsible employee is present during the inspection. The better the preparation, the smoother the inspection process will go.
What are the most common reasons why a crane fails inspection?
The most common reasons for rejection are wear or wire breaks in steel cables, poorly functioning brakes, defective emergency stop provisions, and missing or illegible safety markings. Regular preventive maintenance helps to identify and prevent these issues at an early stage.
Does the inspection obligation also apply to small or mobile lifting systems?
Yes, the inspection obligation applies in principle to all industrial lifting systems, including smaller jib cranes or mobile systems used professionally. The exact requirements may vary depending on the situation, but the starting point is that every system that lifts workers or loads must comply with statutory safety requirements.