Crane Inspections, NDT & Load Testing

You already know why the crane needs to be inspected.

What you need to know is what condition the machine is actually in.

When we find something, we do more than put it on a list.

We help determine what it means and what needs to happen next.

Mondak provides:

• Annual / comprehensive crane inspections
• Periodic crane inspections
• Post-repair inspections
• Post-modification inspections
• Severe-service inspections
• Return-to-service inspections
• Functional testing
• Load testing
• Proof testing
• Nondestructive testing (NDT), performed with a qualified third-party NDT provider
• Wire rope and hoisting-component inspection
• Hydraulic system inspection
• Structural-component inspection
• LMI / RCL and operational-aid evaluation
• Inspection documentation
• Repair of identified deficiencies

Inspection and testing requirements depend on the crane, its application, applicable standards, manufacturer requirements and the work that has been performed.

A good inspection goes considerably deeper than walking around the crane looking for an oil leak.

For construction cranes covered by OSHA 1926 Subpart CC, the annual/comprehensive inspection is required at least every 12 months and must be performed by a qualified person. The inspection includes functional testing and, where necessary, enough disassembly to complete the inspection.

Depending on the crane, inspection areas can include:

• Boom and jib structures
• Structural members
• Welds and high-stress areas
• Fasteners
• Pins and bushings
• Bearings and shafts
• Boom wear pads
• Sheaves and drums
• Wire rope and reeving
• Hooks and hook blocks
• Winches and hoists
• Swing systems
• Brakes and holding systems
• Outriggers and stabilizers
• Hydraulic pumps and motors
• Cylinders
• Valves and manifolds
• Hoses and hard lines
• Hydraulic leakage
• Electrical wiring
• Controllers and operating controls
• Safety devices
• Operational aids
• LMI / RCL systems
• Boom angle and length indication
• Carrier components where applicable

For cranes operating under other rules or applications, inspection intervals and requirements can differ. OSHA's general-industry rules, for example, distinguish between frequent and periodic inspections based on service conditions and manufacturer recommendations.

We inspect the crane that is actually in front of us, not a generic checklist pretending every machine is the same.

A proper NDT inspection is not always a quick test on an assembled crane.

Depending on the component and inspection method, the job may require:

• Component removal
• Disassembly
• Cleaning
• Paint or coating removal
• Surface preparation
• NDT inspection
• Documentation
• Reassembly
• Follow-up repair or additional evaluation

That is why the cost and scope of NDT can vary considerably from one crane to another.

The test itself may be only one part of the job. Getting proper access to the component can be the bigger part.

Some repairs affect parts of the crane directly related to safe operation.

That may include work involving:

• Structural components
• Safety devices
• Operational aids
• Control systems
• Braking systems
• Load-sustaining components
• Hooks
• Winches and hoists
• Critical operating mechanisms

For construction cranes, repairs or adjustments that relate to safe operation require inspection by a qualified person before return to use, including functional testing of the repaired or adjusted parts and other components that may have been affected.

Depending on what was repaired, additional NDT, load testing, manufacturer criteria or engineering involvement may also be appropriate.

Cranes depend heavily on hydraulics, and not every hydraulic problem is visible from outside the machine.

Mondak can evaluate conditions involving:

• Cylinder drift
• External leakage
• Internal leakage
• Damaged cylinder rods
• Pump condition
• Hydraulic pressure
• Flow
• Valve operation
• Relief functions
• Counterbalance and holding valves
• Hoses and hard lines
• Excessive heat
• Contamination

OSHA's construction-crane comprehensive inspection criteria specifically address hydraulic and pneumatic components, leaks, relief-valve operation and cylinder drift, rods, seals and connecting joints.

That aligns well with what Mondak already does every day in hydraulic troubleshooting.

Large cranes working in the United States may combine systems and components from several manufacturers.

A Liebherr, Tadano/Demag, Kobelco, SANY, Zoomlion or other international machine may combine:

• Manufacturer-specific crane electronics
• CAN communication
• Electronic engine controls
• Hydraulic systems from major component manufacturers
• Load-monitoring electronics
• Proprietary sensors
• Unusual diagnostic connections

Mondak has OEM diagnostic software, NEXIQ communication equipment, multi-pin diagnostic capability, ECM programming equipment and direct/bench electronic diagnostic capabilities.

An international brand or unusual diagnostic connector does not automatically stop the troubleshooting process.

Cracked booms, damaged structural members, deformation and critical weld repairs are not treated like ordinary equipment repairs.

Where manufacturer criteria, engineering, NDT or specific return-to-service testing is required, those requirements need to be part of the repair.

ASME B30.5 specifically addresses inspection, testing, maintenance and operation for applicable mobile and locomotive cranes and is one of the standards that can apply alongside regulatory and manufacturer requirements.

We would rather handle a structural concern correctly than pretend every crack is simply another welding job.

The services Mondak most often pairs with a crane inspection:

• Crane Repair
• Material Handling Equipment Repair
• Hydraulic System Diagnostics & Field Repair
• Hydraulic Cylinder Repair & Rebuilding
• Hydraulic Pump, Motor & Valve Repair
• Truck Electrical & Diagnostic Repair
• Diesel Engine Repair
• PTO & Wet Kit Systems
• Portable Line Boring & Pin/Bushing Repair
• Welding, Fabrication & Machining
• Mobile Field & Emergency Service