Crane Inspection Guide
Regular crane inspections are the essential foundation for maximum safety in daily operations. They not only protect people and machinery from accidents but also reduce the risk of costly damage and unplanned downtime. Consistent inspections further ensure smooth operations and serve as an indispensable record for authorities and insurers that all legal requirements are met.
Basics of Crane Inspection According to Legal Requirements
A crane inspection is more than a technical routine—it is a legal obligation for every business owner, with employee safety and the protection of valuable assets at its core. A complex network of regulations, led by the German Ordinance on Industrial Safety and Health (BetrSichV) and DGUV rules, forms the legal framework. These rules define not only that inspections must be carried out but also how and by whom. Consistent compliance is crucial to maintaining operating permits, minimizing liability risks, and fostering a sustainable culture of workplace safety.
Legal Framework and Standards
The legal basis consists of the BetrSichV, supplemented by DGUV Rule 100-500 and the Accident Prevention Regulations (UVV). These standards specify how crane inspections must be conducted, what documentation must be maintained, and who qualifies as a competent person or expert inspector. Legislators require companies to maintain all work equipment—including cranes—so that human life is never at risk. Accident prevention and occupational safety rules detail the requirements for lifting gear, attachment points, and safe load handling.
DGUV Regulation 52 for Cranes and Hoists
DGUV Regulation 52 (also known as DGUV V52) and the former BGV D8 define the inspection scope for all crane types. Before any initial acceptance test, an expert inspection verifies technical condition, functionality, and load capacity. This is followed by regular periodic inspections by qualified inspectors. Additional DGUV rules apply to related equipment, such as lifting chains or spreader beams. Tenwinkel test weights ensure accurate load simulation in compliance with standards and provide a verifiable record of all test results.
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Types and Execution of Crane Inspections
A crane inspection is not a one-time event—it accompanies the equipment throughout its entire lifecycle, with each phase presenting specific requirements. It begins with the comprehensive acceptance inspection before first commissioning. This is followed by legally mandated periodic inspections during operation to detect wear and material fatigue early. An extraordinary inspection is required whenever significant structural changes are made. In all cases, standard-compliant test weights are essential to reliably simulate real loads and confirm load capacity beyond doubt.
Inspection Before First Commissioning
Before putting new cranes—whether gantry cranes, tower cranes, or truck-mounted cranes—into operation, the law requires a full acceptance inspection. Crane test weights simulate real-world forces and verify control systems and braking performance under realistic working conditions. This ensures the manufacturer’s compliance with setup standards, correct mounting, and flawless electrical systems. Only after a positive expert assessment may the crane enter service.
Periodic Inspections for Safe Operation
During its service life, each crane must undergo regular inspections to detect wear, corrosion, or climate-related changes early. The focus is on crane safety, load limits, and changes in service life. Scheduled inspection intervals minimize the risk of accidents and protect both employees and third parties from unexpected hazards.
Inspection After Significant Modifications
Technical changes, structural modifications, replacement of load-bearing components, or new control systems trigger an extraordinary inspection. The same applies when relocating the crane to a new site: new operating conditions require verification of setup, lifting gear, and travel paths. Spreaders allow inspectors to quickly check whether load capacity is affected under the altered conditions. This ensures long-term safe and economical equipment use.
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FAQ
How often must a crane be inspected?
The inspection interval depends on the operating conditions and risk assessment of each crane. Typically, interim visual and functional checks are performed, with a full main inspection every twelve months. Additional intervals apply in cases of heavy use or special incidents.
What is a crane inspection?
It is the systematic examination of all safety-relevant components, controls, and lifting gear. It ensures that design, function, and condition comply with legal requirements and that the crane can safely lift and move loads.
How is a crane inspection carried out?
The inspector performs a visual check, records measurements, and conducts load tests with standard-compliant weights. Tenwinkel test weights allow infinitely variable adjustment to the required test load—whether partial or full load.
Who is authorized to inspect a crane?
Only qualified and competent persons or independent expert inspectors may carry out crane inspections. They must have proven expertise, experience with lifting equipment, and familiarity with DGUV, UVV, and other relevant standards.
What does “tested according to DGUV” mean?
It confirms that all inspection steps were carried out in accordance with DGUV rules—from DGUV Rule 100-500 to DGUV Regulation 52—and that the crane meets all occupational safety objectives.
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