Crane definitions and scope

A crawler crane is a rotating superstructure with engine, operating machinery, and boom mounted on a base with crawler treads for travel and is used to hoist and swing loads at various radii. See 1910.180(a)(1) for the formal definition.

• Key distinguishing features: tracked (crawler) base for site travel, rotating superstructure, and boom used to hoist and swing loads.
• Practical implication: mobility on soft or uneven ground and different stability characteristics than wheeled or truck-mounted cranes, which affects load ratings and setup (see 1910.180(c)).

A locomotive crane is a rotating superstructure with power plant, operating machinery, and boom mounted on a base or car equipped for travel on railroad track, and it may be self-propelled or propelled by an outside source. See 1910.180(a)(2).

• Coverage: Locomotive cranes that retain the fundamental characteristics described (drums and ropes; powered by internal combustion or electric motors) are covered under this part when used as lifting cranes per 1910.180(b)(1).
• Note: cranes designed specifically for railway and automobile wreck clearance are excepted by 1910.180(b)(1).

A truck crane is a rotating superstructure with powerplant, operating machinery, and boom mounted on an automotive truck equipped with a powerplant for travel. See 1910.180(a)(3).

• Difference from wheel-mounted (wagon) cranes: a wheel-mounted crane may be mounted on a separate base or platform with rubber-tired wheels and can be self-propelled by the superstructure engine or a separate engine; see 1910.180(a)(4).
• Practical effect: mounting type affects travel, stability, and the specific load-rating and stability calculations required under 1910.180(c).

This section applies to crawler cranes, locomotive cranes, and wheel-mounted cranes of both truck and self-propelled wheel type (and variations that retain the same basic characteristics), when used as lifting cranes. See 1910.180(b)(1).

• Common exception: cranes designed for railway and automobile wreck clearances are excluded per 1910.180(b)(1).
• Note: coverage is limited to cranes that use drums and ropes and are powered by internal combustion or electric motors, per the same paragraph.

All new crawler, locomotive, and truck cranes constructed and used on or after August 31, 1971, must meet the design specifications of ANSI B30.5-1968 as incorporated by reference. See 1910.180(b)(2).

• Practical action: ensure manufacturer's documentation or certification confirms compliance with [ANSI B30.5-1968] as required by 1910.180(b)(2).
• If you operate or procure new cranes, request evidence that design and construction conform to that ANSI code.

Only personnel designated by the employer (i.e., 'designated personnel') are permitted to operate cranes covered by this section. See 1910.180(b)(3).

• "Designated personnel" means those assigned specific responsibilities by the employer or the employer's representative per 1910.180(a)(6).
• Practical steps: document designation, required qualifications/training, and limit operation to those employees to meet 1910.180(b)(3).

The margin of stability for load ratings is determined by taking a percentage of the tipping (balance) loads for booms of specified lengths and radii in the least stable direction relative to the mounting. See 1910.180(c)(1)(i).

• In practice: engineers calculate the tipping load (the load that would cause tipping) under static conditions, then apply the stability-percentage factors in 1910.180(c)(1)(i) to set allowable load ratings.
• Remember to consider the least-stable boom position when determining ratings as required by the provision.

Maximum load ratings are set as percentages of tipping loads and vary by mounting: locomotive (without outriggers) and truck/wheel-mounted (with or without outriggers) generally have 85% maximum, crawler without outriggers 75%, crawler with outriggers 85%, and locomotive using outriggers 80%; see the load rating table in 1910.180(c)(1)(i).

• Special minimum for locomotive booms: if applying 85% would yield less than a 30,000 pound-feet net stabilizing moment about the rail, the stabilizing moment shall be at least 30,000 pound-feet (note in the table at 1910.180(c)(1)(i)).
• Practical tip: always check the table values in 1910.180(c)(1)(i) and apply the minimum moment requirement where relevant.

For locomotive cranes, "tipping" occurs when half of the wheels farthest from the load leave the rail; the crane must be standing on track level within 1 percent grade; and the load radius is measured horizontally from the projected axis of rotation to the rail support surface to the center of the vertical hoist line with the load applied. See 1910.180(c)(1)(ii)(a)-(c).

• Practical application: perform rating calculations using the track condition (level within 1%) and the defined radius measurement method in 1910.180(c)(1)(ii)(b)-(c).
• Ensure setup documentation records track grade and radius method used to validate ratings.

No — tipping loads used to determine ratings must be applied under static conditions only, without dynamic effects of hoisting, lowering, or swinging. See 1910.180(c)(1)(ii)(d).

• Practical consequence: engineers and manufacturers must base rated capacities on static tipping calculations; operators must separately account for dynamic factors in safe operation, as noted in 1910.180(c)(1)(iv).
• If operations introduce dynamic loads, reduce working loads or adjust operating procedures accordingly.

Yes — the weight of all auxiliary handling devices such as hoist blocks, hooks, and slings must be considered part of the load when determining load ratings. See 1910.180(c)(1)(ii)(e).

• Practical step: add the weight of load-attaching equipment to the planned load weight when checking crane capacity per 1910.180(a)(26) (definition of load) and 1910.180(c)(1)(ii)(e).
• This prevents exceeding rated capacity and reduces tipping or overload risk.

Stipulations governing application of the stability percentages for crawler, truck, and wheel-mounted cranes must follow the Crane Load-Stability Test Code, SAE J765, as incorporated by reference. See 1910.180(c)(1)(iii).

• Practical implication: use SAE J765 procedures when performing stability and load-stability testing for these crane types.
• Confirm that manufacturer load tables and stability tests reference SAE J765 per 1910.180(c)(1)(iii).

A substantial and durable rating chart with clearly legible letters and figures must be permanently attached to the crane cab in a location easily visible to the operator while seated at the controls. See 1910.180(c)(2).

• Practical actions: ensure the chart is corrosion- and weather-resistant, positioned within the operator's normal sight lines, and updated if equipment configuration (outriggers, jib) changes.
• If the chart becomes illegible, replace it promptly to comply with 1910.180(c)(2).

Prior to initial use, all new and altered cranes must be inspected to ensure compliance with the provisions of this section. See 1910.180(d)(1).

• Practical checklist: perform functional tests, verify load charts, inspect ropes, drums, brakes and safety devices, and document the initial inspection before placing the crane in service as required by 1910.180(d)(1).
• Keep inspection records as part of your safety program to demonstrate compliance.

Frequent inspections are required at intervals from daily to monthly, while periodic inspections are at intervals from 1 to 12 months or as the manufacturer recommends. See 1910.180(d)(2) and 1910.180(d)(2)(i)-(ii).

• Examples of frequent inspection items (daily): control mechanisms for maladjustment interfering with operation and control components for excessive wear or contamination per 1910.180(d)(3)(i)-(ii).
• Practical guidance: conduct visual and operational checks during each shift or day of operation and document findings; escalate defects that may constitute safety hazards for repair or removal from service.

Outriggers are extendable or fixed metal arms attached to the crane base that rest on supports at their outer ends and are used to increase machine stability. See 1910.180(a)(31).

• Effect on ratings: using outriggers fully extended changes allowable load percentages (e.g., locomotive using outriggers 80%, crawler using outriggers 85%, truck/wheel with outriggers 85%) per the table in 1910.180(c)(1)(i).
• Practical action: always deploy and support outriggers per manufacturer instructions and verify crane load chart ratings are based on the outriggers' configuration.

A counterweight is a weight used to supplement the machine weight to provide stability for lifting working loads. See 1910.180(a)(20).

• Role in operations: counterweights increase the tipping moment opposite the load and are integral to achieving rated capacities and stable lifts; removing or changing counterweights affects the crane's stability and must be reflected in load charts.
• Practical check: never alter or remove counterweights without following manufacturer guidance and updating load ratings in accordance with 1910.180(c).

Yes — "load (working)" includes the external load in pounds and the weight of load-attaching equipment such as load blocks, shackles, and slings. See 1910.180(a)(26).

• Planning implication: always add the weight of hooks, blocks, slings, and any rigging hardware to the object's weight when checking the crane's load chart and capacity per 1910.180(c)(1)(ii)(e).
• Failure to include these weights can result in exceeding rated capacity and increase tipping or component overload risks.

A standby crane is a crane not in regular service but used occasionally or intermittently as required. See 1910.180(a)(36).

• Applicability: when a standby crane is used as a lifting crane, the requirements of this section apply during its use (see general scope in 1910.180(b)(1)).
• Practical action: maintain inspections, load charts, and designated operator controls for standby cranes before and during any intermittent use per 1910.180(d).

If the employer's assessment identifies a potential for head injury from falling objects or overhead hazards to the crane operator, the operator must wear a protective helmet. See 1910.180(a)(18) (definition of cab) and OSHA's Letter of Interpretation on head protection at https://www.osha.gov/laws-regs/standardinterpretations/2024-06-06-2.

• Required standard: head protection must meet one of the consensus ANSI standards incorporated by reference as described in the interpretation (see the letter at https://www.osha.gov/laws-regs/standardinterpretations/2024-06-06-2).
• Employer duty: perform a hazard assessment under 1910.132(d)(1) and require helmets where overhead lifting or other falling-object risks are present, per the interpretation guidance.

Periodic inspections must include the items listed in paragraph (d)(3) plus additional structural and mechanical checks identified in paragraph (d)(4). Under 1910.180(d)(4), inspectors must look for things such as:

• Deformed, cracked, or corroded members in the crane structure and boom (1910.180(d)(4)(i)).
• Loose bolts or rivets (1910.180(d)(4)(ii)).
• Cracked or worn sheaves and drums (1910.180(d)(4)(iii)).
• Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and locking devices (1910.180(d)(4)(iv)).

Inspections should be done at intervals determined by the crane’s activity, service severity, and environment as discussed in 1910.180(d)(2)(ii) and as specifically required by (d)(4) itself.

You must inspect air and hydraulic systems daily for deterioration or leakage. The standard specifies daily checks for deterioration or leakage in air or hydraulic systems in 1910.180(d)(3)(iv). Daily inspection helps catch fluid leaks or worn hoses before they create unsafe operating conditions.

Crane hooks must be removed from service if they have cracks, more than 15 percent increase in throat opening, or more than a 10° twist from the plane of the unbent hook. 1910.180(d)(3)(v) requires removal for hooks with those deformations or cracks because they compromise strength and safe lifting capability.

Running ropes in use must be inspected at least once a month, and ropes that have been idle for a month or more must be thoroughly inspected before use. 1910.180(g)(1) requires monthly inspections of all ropes in use, and 1910.180(g)(2)(ii) requires a thorough inspection after a rope has been idle for a month or more. Inspections must be performed by an appointed or authorized person who documents the inspection and approves the rope for further use.

Inspection certification records must include the date of inspection, the signature of the person who performed the inspection, and the crane serial number or other identifier; critical items in use must be certified monthly. 1910.180(d)(6) requires monthly certification records for critical items such as brakes, crane hooks, and ropes, and those records must be kept readily available.

If a crane has been idle 1 month or more but less than 6 months, it needs an inspection meeting paragraph (d)(3) and 1910.180(g)(2)(ii) before placing it in service; if idle 6 months or more, it requires a complete inspection per paragraphs (d)(3) and (d)(4) and 1910.180(g)(2)(ii). See 1910.180(d)(5)(i)-(ii).

Standby cranes must be inspected at least semiannually according to paragraph (d)(3) and 1910.180(g)(2)(ii). 1910.180(d)(5)(iii) also notes that cranes exposed to adverse environments should be inspected more frequently.

Manufacturers must test new production cranes to ensure operational functions meet requirements, including load hoisting/lowering, boom hoisting/lowering, swinging, traveling, and safety devices. 1910.180(e)(1) and 1910.180(e)(1)(i) list those functions; if final assembly involves parts from different manufacturers, testing must be done at final assembly (1910.180(e)(1)(ii)). Certified test results must be made available (1910.180(e)(1)(iii)).

Rated-load tests must not exceed 110% of the rated load at any selected working radius, and any rerating above original load ratings must be approved by the crane manufacturer or final assembler. 1910.180(e)(2)(ii) caps test loads at 110% of rated load, 1910.180(e)(2)(iii) describes rerating test procedures, and 1910.180(e)(2)(iv) forbids rerating above original ratings without manufacturer or final assembler approval.

No — after adjustments and repairs, the crane must not be operated until all guards are reinstalled, safety devices reactivated, and maintenance equipment removed. 1910.180(f) requires these steps to ensure the crane is safe before returning it to service.

The hoist rope must not be wrapped around the load, and the load must be attached to the hook by slings or other approved devices. 1910.180(h)(2)(i) prohibits wrapping the hoist rope around the load, and 1910.180(h)(2)(ii) requires use of slings or approved devices for attachment.

No — the operator may not leave the controls while the load is suspended, and no person should be permitted to stand or pass under a suspended load. 1910.180(h)(4)(i) and 1910.180(h)(4)(ii) make these requirements clear to prevent falls and crush hazards.

Outriggers must be used when the load at that radius exceeds the manufacturer’s rated load without outriggers, and wood blocks used to support outriggers must be strong, defect-free, and wide/long enough to prevent crushing or shifting. 1910.180(h)(3)(ix) and subparts (ix)(a)-(c) (1910.180(h)(3)(ix)(a), 1910.180(h)(3)(ix)(b), 1910.180(h)(3)(ix)(c) set those wood-block conditions.

When two or more cranes are used to lift one load, one designated person must be responsible for analyzing the lift and instructing all involved personnel on proper positioning, rigging, and movements. 1910.180(h)(3)(xii) requires a single coordinator to plan and direct the operation to ensure safety and communication.

You must not lower a load or boom below the point where fewer than two full wraps of rope remain on their respective drums. 1910.180(h)(3)(x) prevents rope slippage off the drum and loss of load control.

The operator shall test the brakes each time a load approaching the rated load is handled by raising the load a few inches and applying the brakes. 1910.180(h)(3)(viii) requires this to confirm braking performance under near-capacity conditions.

No — you cannot increase a crane’s original rated load unless the change is approved by the crane manufacturer or final assembler. 1910.180(e)(2)(iv) prohibits rerating above original load ratings without that approval.

You must inspect rope reeving to ensure it complies with the manufacturer's recommendations and remove or correct any noncompliant reeving. 1910.180(d)(3)(vi) requires checking reeving as part of the inspection items in (d)(3).

Inspect electrical apparatus for malfunction, signs of excessive deterioration, and accumulation of dirt or moisture and correct any unsafe conditions. 1910.180(d)(3)(vii) lists those items as part of required inspection checks.

OSHA requires head protection when there is a potential for injury from falling objects around cranes, and that protection must meet ANSI Z89.1 consensus standards incorporated by reference. OSHA’s interpretation clarifies that head protection is required where operators are exposed to overhead hazards and that helmets must comply with consensus standards such as ANSI Z89.1; see the OSHA interpretation on head protection for crane operators at https://www.osha.gov/laws-regs/standardinterpretations/2024-06-06-2. For general OSHA requirements on employer protection duties, see 1910.

They must be kept in the toolbox and not left loose in or around the cab. See 1910.180(i)(3)(ii) which states that “Tools, oil cans, waste, extra fuses, and other necessary articles shall be stored in the tool box, and shall not be permitted to lie loose in or about the cab.”

• Storing small items in the toolbox prevents them from falling or shifting while the crane moves, reducing pinch, trip, and impact hazards.
• Train operators and maintenance staff to check the toolbox before operation and to secure all loose items after maintenance.

(Referenced standard: 1910.180(i)(3)(ii).)

Refueling from small portable containers must use an approved safety can with an automatic closing cap and flame arrester, and you must not refuel with the engine running. See 1910.180(i)(4)(i) and 1910.180(i)(4)(ii).

• "Approved" for safety cans is defined in 1910.155(c)(3), so use only containers that meet that requirement.
• Always shut down the engine before refueling to eliminate ignition sources and reduce fire risk.
• Keep a fire extinguisher nearby per 1910.180(i)(5)(i).

(Referenced standards: 1910.180(i)(4)(i), 1910.180(i)(4)(ii), and 1910.155(c)(3).)

A carbon dioxide, dry chemical, or equivalent fire extinguisher must be kept in the cab or near the crane, and operating and maintenance personnel must be made familiar with its use and care. See 1910.180(i)(5)(i) and 1910.180(i)(5)(ii).

• Place the extinguisher where the operator can quickly reach it from the cab or immediate vicinity.
• Provide hands-on familiarization and basic maintenance checks (pressure, seals, accessibility) to operators and maintenance staff so they can respond safely in an emergency.

(Referenced standard: 1910.180(i)(5)(i)-(ii).)

You must not swing a locomotive crane into a position where railway cars on an adjacent track might strike it until you confirm cars on that track are not being moved and proper flag protection is in place. See 1910.180(i)(6).

• Stop and verify that adjacent-track operations are halted before moving the crane into a swinging position that could be struck by rail cars.
• Establish flagging or other positive protection and communication with rail personnel to prevent unexpected car movement.
• Document the check and the protective measures as part of your job briefings for switching or crane operations near tracks.

(Referenced standard: 1910.180(i)(6).)

Operations near overhead electric lines must comply with the electrical-safety procedures referenced in [1910.333(c)(3)]. See 1910.180(j) and 1910.333(c)(3).

• Follow the minimum approach distances, de-energizing, insulating, or using barriers as required by the electrical safety rules in 1910.333(c).
• Plan crane work near lines: identify line voltage, establish exclusion zones, and assign a qualified person to implement controls.
• Use spotters or dedicated observers to maintain safe clearance during slewing, hoisting, or boom operations.

(Referenced standards: 1910.180(j) and 1910.333(c)(3).)

Crane operators must wear protective helmets when there is a potential for head injury from falling objects or other overhead hazards; the helmets must meet an ANSI Z89.1 consensus standard referenced by OSHA. OSHA explained this in its interpretation about head protection for crane operators: see the June 6, 2024 letter at https://www.osha.gov/laws-regs/standardinterpretations/2024-06-06-2 and the general head protection rule in 29 CFR 1910.

• The OSHA interpretation states that if an operator can be struck by falling objects while lifting loads, [29 CFR 1910.135(a)(1)] applies and head protection is required; acceptable helmets must comply with ANSI Z89.1 series standards as incorporated by reference (see the OSHA interpretation at https://www.osha.gov/laws-regs/standardinterpretations/2024-06-06-2).
• Employers must assess hazards per [29 CFR 1910.132(d)(1)] and provide helmets when overhead hazards exist.
• Employers may require helmets at all times for certain operations as a conservative safety measure.

(Referenced interpretation: https://www.osha.gov/laws-regs/standardinterpretations/2024-06-06-2; see also general OSHA rule set at 1910.)

No — machines must not be refueled while the engine is running. See 1910.180(i)(4)(ii).

• Always shut down the engine and allow hot components to cool as appropriate before refueling to reduce ignition and burn risks.
• Follow the approved portable container requirements in 1910.180(i)(4)(i) and the "approved" definition in 1910.155(c)(3).

(Referenced standard: 1910.180(i)(4)(ii).)