Overhead and gantry cranes - California

California follows federal OSHA regulations for overhead and gantry cranes. The California state OSHA plan adopts federal OSHA standards for private sector and state and local workplaces. However, additional unique state-specific standards exist.  

Licensing of certifier. California regulates the licensing of any person engaged in the testing, examination and/or certification of cranes used in lifting more than three tons. These regulations govern the application process, license approval and issuance, the duration and renewal of the license, fees (for application, renewal, and examination), denial of license, and revocation or suspension of the license (8 CCR 344.60 – 344.67).

Duties of licensed certifier. The regulations also set forth the duties and recordkeeping requirements of a licensed crane certifier (8 CCR 344.80).

General safety orders. Overhead and gantry cranes with a maximum capacity of more than one ton are subject to general safety orders. These general safety orders are found in 8 CCR 4481 and include the following:

• Posted warnings required by regulation as well as supplied with the equipment by the manufacturer must be maintained in legible condition.
• All exhaust pipes, turbochargers, and charge air coolers must be insulated or guarded where inadvertent contact by employees (except for maintenance and repair employees) is possible in the performance of normal duties.
• Load hooks, ball assemblies and load blocks must be of sufficient weight to overhaul the line from the highest hook position for boom or boom and jib lengths and the number of parts of the line in use.
• Hook and ball assemblies and load blocks:
  • On mobile cranes must be marked with their rated capacity and weight.
  • Must be equipped with latches.
  • EXCEPTION: Hooks without latches, or with latches removed or disabled, must not be used unless a qualified person has determined that it is safer to hoist and place the load without latches (or with the latches removed/tied-back).

Design, construction, and installation. Cranes with a manufacturer-rated lifting capacity of more than 2000 pounds must be designed, constructed, and installed in accordance with the standards set forth in 8 CCR 4884.

Additional orders. Additional general safety orders apply to the following categories for overhead and gantry cranes and any modification of these cranes which retain their characteristic features:

• Access to the cage, cab, or machine house (8 CCR 4887)
• Outdoor cages, cabs, or machine houses (8 CCR 4888)
• Warning devices (8 CCR 4889)
• Illumination (8 CCR 4895)
• Controllers (8 CCR 4896)
• Hoist limit device (8 CCR 4897)
• Brakes for hoists (8 CCR 4898)
• Foot brakes pedal (8 CCR 4899)
• Locking device (8 CCR 4900)
• Brakes for bridge and swinging motion (8 CCR 4901)
• Boom hoist mechanisms (8 CCR 4902)
• Runway travel limit device (8 CCR 4903)
• Trolley bumpers (8 CCR 4904)
• Bridge or gantry bumpers (8 CCR 4905)
• Truck wheel guards and rail sweeps (8 CCR 4906)
• Capacity marking and load indication (8 CCR 4907)
• Hoisting ropes (8 CCR 4908)
• Runway repair (8 CCR 4009)
• Crane runways (8 CCR 4910)
• Rails (8 CCR 4911)
• Clearances (8 CCR 4912)
• Wind indicators and rail clamps (8 CCR 4913)

(8 CCR 4886 – 4913).

Overhead crane clearance. For on-floor operated overhead cranes, a suitable work platform with means of access must be provided, attached to the building structure, or on the overhead crane bridge, giving ready and safe access to electrical control cabinets for service, maintenance or repair (8 CCR 2561.3).

Testing intervals. Proof load tests of cranes must be carried out at the following intervals:

• In the case of new cranes, before being taken into initial use and every four years thereafter.
• In the case of uncertificated cranes which have been in use, at the time of initial certification and every four years thereafter.
• In the case of major modifications or repairs to important structural components, before they are returned to service.
• When certificated equipment is out of service for 6 months or more beyond the due date of a certification inspection, an examination equivalent to an initial certification, including proof load test, must be performed before the equipment re-enters service (8 CCR 5022(a)).

Testing exceptions. For cranes having a maximum rated capacity greater than one ton but not exceeding three tons, the following testing exceptions found in 8 CCR 5022(a) apply:

• Prior to initial use, the crane must be tested using the criteria in 8 CCR 5022(c).
• Testing must be performed by, or under the direction of, a qualified person. The test reports must be retained on file and available with each crane.
• Quadrennial (every 4 years after initial) proof load tests are not required.
• Disassembly and reassembly of equipment do not require recertification of the equipment provided that the equipment is reassembled and used in a manner consistent with its certification.

Criteria. The proof load testing criteria for cranes are found in 8 CCR 5022(c), and are as follows:

• Proof load tests must be based on the manufacturer's load ratings for the conditions of use and must consist of the application of a proof load as large as possible but not exceeding 110 percent of the maximum load ratings for the boom on the crane.
• Proof loads must be applied at the designed maximum and minimum boom angles or radii or as close to these as practicable and at such intermediate radii as the certifying agency may deem necessary.
• Overhead cranes must be tested to a proof load as close as possible but not exceeding 125 percent of the manufacturer's load rating.
• Overhead cranes must be tested by traversing the proof load weight the full length of the track, bridge/runway(s) and crossovers, in all directions capable of operation, where practicable.
• In cases of foreign manufacture, the manufacturer's specifications will be subject to approval by the certified agent as being equivalent to U.S. practice.
• The weight of all auxiliary handling devices such as, but not limited to, magnets, hooks, slings, and clamshell buckets must be considered part of the load, except lifting devices which are designed as an integral part of the crane.
• Other methods of proof load testing may be substituted for the above where acceptable to the Division of Industrial Safety.

Examination. An examination must be carried out in conjunction with each proof load test. The certificating agency must make a determination as to requirements for the correction of deficiencies found. The examination requirements are found in 8 CCR 5022(d), and must cover the following points:

• All functional operating mechanisms for improper function, maladjustment, cracks, distortion, or excessive component wear, with particular attention to sheaves, pins, and drums, bearings, shafts, gears, rollers, and locking devices. This must include operation with partial load, in which all functions and movements, including, where applicable, maximum possible rotation in both directions, are performed.
• All safety devices and operational aids for proper operation (including significant inaccuracies).
• Deterioration, abnormal wear or performance, or leakage in lines, tanks, valves, drains, pumps, joints, fittings and other parts of pneumatic, hydraulic or other pressurized systems.
• Loose gear components (i.e. hooks, etc.), including wire rope and wire rope terminals and connections, with particular attention to sections of wire rope exposed to abnormal wear and sections not normally exposed for examination. Cracked or deformed hooks must be discarded.
• Rope reeving for compliance with certified agent's recommendations.
• Deformed, cracked, or excessively corroded members in crane structure and boom. • Loose bolts, rivets, or other connections.
• Worn, cracked, or distorted parts affecting safe operation.
• Excessive wear on and free operation of brake and clutch system parts, linings, pawls, and ratchets.
• Load, boom angle, or other indicators shall be checked for any inaccuracy.
• It must be ascertained that there is a durable rating chart visible to the operator, covering the complete range of the certified agent's capacity ratings at all operating radii, for all permissible boom lengths and jib length, with alternate ratings for optional equipment affecting such ratings. Necessary precautions or warnings must be included and operating controls marked, or an explanation of controls must be posted at the operator's position to indicate function.
• Careful examination of the junction areas of removable boom sections, particularly for proper seating, cracks, deformities, or other defects in securing bolts and in the vicinity of such bolts.
• It must be ascertained that no counterweights in excess of the certified agent's specifications are fitted.
• Welds for cracks.
• Electrical components and wiring for cracked or split insulation and loose or corroded terminations.
• Operator seat (when applicable): Installed and serviceable.
• Steps, ladders, handrails, handholds, guards, where provided or required by other sections of these Orders: In usable and safe condition.
• Such other examinations as deemed necessary under the circumstances.