29 CFR 1910.179: OSHA Overhead and Gantry Cranes

Regulatory citation: 29 CFR 1910.179, Overhead and Gantry Cranes (Materials Handling and Storage, Subpart N)

What Is the OSHA Overhead and Gantry Crane Standard?

Section 1910.179 applies to overhead and gantry cranes in general industry, including semigantry, cantilever gantry, wall cranes, storage bridge cranes and others having the same fundamental characteristics.

The standard covers crane design and markings, who may operate a crane, inspection, testing, maintenance, rope inspection and the safe handling of loads. Cranes constructed and installed on or after August 31, 1971 must 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.

Why Crane Safety Matters

Worn hooks, damaged rope, failed brakes or a poorly rigged load can drop a load without warning. Regular inspection and disciplined operation are the main defenses.

Core Obligations

1. Mark the Rated Load and Control Modifications (1910.179(b))

The rated load of the crane must be plainly marked on each side of the crane, and if the crane has more than one hoisting unit, each hoist must have its rated load marked on it or its load block. A crane may be modified and rerated only if the modifications and the supporting structure are checked thoroughly for the new rated load by a qualified engineer or the equipment manufacturer. The crane must then be tested under paragraph (k)(2) and the new rated load displayed.

2. Allow Only Designated Operators (1910.179(b)(8))

Only designated personnel may operate a crane covered by this section.

3. Inspect Before Initial Use and on a Set Schedule (1910.179(j))

New and altered cranes must be inspected before initial use. In regular service, the standard divides inspections into two classes. Frequent inspections occur at daily to monthly intervals and cover items such as functional operating mechanisms, air or hydraulic system leaks, hooks with deformation or cracks, hoist chains and rope reeving. Hooks need visual inspection daily and a monthly inspection with a certification record that includes the date, the signature of the inspector and an identifier of the hook. Hoist chains also need monthly inspection with a similar certification record. Periodic inspections occur at 1 to 12 month intervals, depending on activity, severity of service and environment, and add checks for deformed, cracked or corroded members, loose bolts, worn sheaves, drums and brake parts, and similar defects.

4. Inspect Idle Cranes Before Returning Them to Service (1910.179(j)(4))

A crane idle for 1 month or more, but less than 6 months, must receive an inspection meeting the frequent inspection items and the rope inspection requirements before it is placed back in service. A crane idle for more than 6 months must receive a complete inspection meeting the periodic inspection items and the rope inspection requirements.

5. Test New, Altered and Rerated Cranes (1910.179(k))

New and altered cranes must be operationally tested before initial use, including hoisting and lowering, trolley and bridge travel, and limit switches and locking and safety devices. Test loads must not be more than 125 percent of the rated load unless the manufacturer recommends otherwise, and test reports must be kept readily available to appointed personnel.

6. Run a Preventive Maintenance Program (1910.179(l))

A preventive maintenance program based on the crane manufacturer's recommendations must be established. Before adjustments or repairs, the crane must be moved out of the way, controllers placed in the off position, the main or emergency switch locked open, and warning signs posted. Unsafe conditions found during inspection must be corrected before the crane is returned to operation.

7. Inspect Running Ropes Monthly (1910.179(m))

A thorough inspection of all ropes must be made at least once a month. The monthly inspection needs a certification record with the date, the inspector's signature and an identifier for the ropes inspected. Inspectors look for deterioration such as reduced diameter, broken or worn wires, damaged end connections and severe kinking or crushing. Rope that has been idle for a month or more due to shutdown or storage of a crane must be thoroughly inspected before it is used.

8. Handle Loads Safely (1910.179(n))

The crane must not be loaded beyond its rated load except for test purposes. Loads must be secured and balanced before being lifted more than a few inches. There must be no hoisting, lowering or traveling while any employee is on the load or hook, and the operator must avoid carrying loads over people. At least two full wraps of rope must remain on the drum, side pulls require specific authorization from a responsible person, and the upper limit switch must be tried out under no load at the beginning of each operator's shift.

Common Compliance Approaches

Digital Inspection Checklists

Use crane-specific checklists that capture the date, signature and identifiers required for hook, chain and rope records.

Lockout for Crane Maintenance

Fold the crane maintenance precautions into the site's lockout/tagout procedures.

Example: Overhead Crane Compliance in Practice

A fabrication shop runs two 10-ton bridge cranes. Operators check the hook and try the upper limit switch at the start of every shift. A maintenance technician completes the monthly hook, chain and rope inspections and signs a certification record for each crane. During one monthly check, the technician finds broken wires on a hoist rope and tags the crane out. It returns to use only after the rope is replaced. A crane idle for eight months gets a complete inspection before reuse.

Related regulations: OSHA slings, OSHA cranes and derricks in construction, OSHA lockout/tagout.

Note: Section 1910.179 covers overhead and gantry cranes in general industry. Cranes used in construction are covered by Part 1926, Subpart CC. State plan states may set stricter rules.

Frequently Asked Questions

How often must overhead crane ropes be inspected?

All ropes need a thorough inspection at least once a month, documented in a certification record with the date, the inspector's signature and an identifier for the ropes. Rope idle for a month or more must be inspected before use.

What is the maximum load test for an overhead crane?

Test loads must not be more than 125 percent of the rated load unless the manufacturer recommends otherwise. Test reports must be kept readily available.

Who is allowed to operate an overhead crane?

Only designated personnel may operate a crane covered by section 1910.179.