Electric Overhead Travelling (EOT) cranes are among the most critical pieces of lifting equipment in any manufacturing facility. A single failure can result in catastrophic accidents, production shutdowns, and significant legal liability. Yet, many factory owners treat crane inspection as a paperwork exercise rather than a genuine safety activity.

This guide gives you a practical, field-tested checklist that our Chartered Engineers use during statutory inspections — so you know exactly what to look for and what to expect.

Why Crane Inspection Is Non-Negotiable

Under the Factories Act, 1948, every hoist and lifting machine must be thoroughly examined by a Competent Person at least once every 12 months. In Maharashtra, this means obtaining a Form 11 certificate from a Government-Approved Competent Person (GACP) authorized by DISH (Directorate of Industrial Safety and Health).

Failure to comply can result in:

• Prosecution under the Factories Act
• Shutdown of the facility by the Factory Inspector
• Invalidation of insurance claims in the event of an accident
• Personal liability for the occupier and manager

The EOT Crane Inspection Checklist

1. Structural Components

• Bridge girders: Check for cracks, corrosion, deformation, and weld integrity
• End carriages: Inspect for cracks at wheel mounting points and buffer attachments
• Runway rails: Verify alignment, joint gaps, and fastener tightness
• Runway beams and columns: Check for deflection, corrosion, and connection integrity
• Festoon cable supports: Ensure they are secure and not causing cable abrasion

2. Mechanical Components

• Wire rope: Inspect for broken wires, kinks, corrosion, and correct reeving. Replace if broken wires exceed limits per IS 3973
• Drum and sheaves: Check for groove wear, flange cracks, and rope fleet angle
• Hooks: Inspect for cracks (dye penetrant test if required), twist, and throat opening. Verify safety latch function
• Gearboxes: Check oil levels, seals, and listen for abnormal noise during operation
• Brakes: Test holding capacity under rated load; check lining wear and adjustment
• Wheels: Measure flange wear and tread diameter; check for cracks

3. Electrical Components

• Main isolator and panel: Verify labelling, earthing, and condition of contactors and overload relays
• Pendant control: Check for damaged cables, sticky buttons, and correct labelling
• Limit switches: Test upper and lower travel limits; verify they stop motion before physical contact
• Earthing continuity: Measure resistance between metallic structure and earth
• Cable festoon: Check for chafing, damaged insulation, and correct cable management

4. Safety Devices

• Overload protection: Test with calibrated test weights; verify trip point
• Anti-collision devices: Functional test where multiple cranes share a runway
• End stops and buffers: Check condition and secure attachment
• Warning horn/bell: Functional test
• Access ladders and walkways: Inspect for corrosion, missing rungs, and handrail integrity

5. Load Testing

For new installations or after major repairs, a proof load test at 125% of Safe Working Load (SWL) is mandatory. For periodic inspections, a rated load test at 100% SWL is performed to verify brake holding and structural integrity.

Common Deficiencies Found During Inspections

Based on our experience across hundreds of crane inspections in Maharashtra and across India, the most frequently found deficiencies are:

1. Wire rope deterioration — particularly at the drum end and at the hook block
2. Brake lining wear — brakes that hold under no-load but slip under rated load
3. Limit switch bypass — operators bypassing upper limit switches to gain extra hook height
4. Inadequate earthing — especially on older cranes where earthing connections have corroded
5. Missing or damaged safety latches on hooks

What Happens After Inspection?

After a thorough inspection, the Competent Person issues:

• Form 11 (Certificate of Examination of Hoist or Lift) — mandatory for all cranes under the Factories Act
• A detailed inspection report listing all deficiencies with recommended corrective actions
• A Safe Working Load (SWL) plate recommendation if the existing one is incorrect

If critical deficiencies are found, the crane must be taken out of service until repairs are completed and re-inspected.

How Often Should You Inspect?

Inspection Type	Frequency	Who Can Perform
Statutory Thorough Examination	Every 12 months	Govt. Approved Competent Person
Pre-shift Visual Check	Daily	Trained crane operator
Monthly Maintenance Check	Monthly	Qualified maintenance technician
Post-repair Inspection	After any repair	Competent Person

Conclusion

A rigorous crane inspection programme is not just a legal obligation — it is the foundation of a safe workplace. If you operate EOT cranes in Maharashtra or anywhere in India, ensure your inspections are conducted by a qualified, Government-Approved Competent Person who can issue the required statutory certificates.

Maysar Services conducts statutory crane inspections and issues Form 11 & Form 13 certifications across Maharashtra and India. Contact us to schedule your next inspection.