Cargo handling gear requirements

Under 1918.61(a) the employer must have all employer‑provided gear inspected by the employer or a designated person before each use and, when appropriate, during use to ensure it is safe. The inspection requirement is stated in 1918.61(a).

• Inspectors should look for obvious defects (cracks, deformations, excessive wear, corrosion, missing parts, or other damage) and remove unsafe gear from service until repaired.
• Use a written inspection checklist and keep records when required by other sections (see 1918.61(i)).

Under 1918.61(b) the safe working load of gear must not be exceeded, and any employer‑provided cargo handling gear with an SWL greater than five short tons (10,000 lbs.) must have its SWL plainly marked. This requirement appears in 1918.61(b)(1) and 1918.61(b)(2).

• Practically, ensure operators can readily see the SWL marking at the rigging or on the device before lifting.
• If the SWL is unknown or unreadable, do not use the gear until it is re‑marked following testing or manufacturer's documentation.

Under 1918.61(c) any article of stevedoring gear that is hoisted by ship's gear and weighs more than 2,000 lbs must have its weight plainly marked. See 1918.61(c).

• This applies to items the ship’s gear lifts (for example, large pallets or skids) rather than small fittings.
• Use durable, legible markings (stamped plate, paint, or plate) so the weight is obvious to crane operators and riggers.

Under 1918.61(e) each certification required by 1918.61 must be performed in accordance with part 1919 of the chapter by a person who is currently accredited by OSHA as provided in that part. See 1918.61(e).

• In practice, that means only an OSHA‑accredited certifier (per 1919) may perform required proof load tests and issue the certification documents.
• Employers must ensure the certifier’s accreditation is current before using their certificates for compliance.

Under 1918.61(f)(1) "special stevedoring gear" is gear whose strength depends on components other than commonly used stock items (like shackles, ropes, or chains), and if it has an SWL greater than five short tons it must be inspected and tested as a unit before initial use. See 1918.61(f)(1).

• Examples include custom fabricated spreaders, specialized lifting frames, or multi‑part custom bridles whose capacity depends on the whole assembly.
• If such gear is structurally repaired after damage, it must be inspected and retested before being returned to service.

Under 1918.61(f)(2) and Table A, gear must be proof load tested to the amounts shown in the table: for SWL up to 20 short tons test to 25% in excess; for 20 through 50 short tons test to 5 short tons in excess; and for over 50 short tons test to 10% in excess. See 1918.61(f)(2).

• Example: a 10‑ton SWL device requires proof testing to 12.5 tons (10 t + 25%).
• Ensure an OSHA‑accredited tester performs and documents the test per 1918.61(e).

Under 1918.61(g) every spreader (not part of ship's gear) used to handle intermodal containers must be inspected and tested before initial use to a proof load equal to 25 percent greater than its rated capacity, and retested after any structural repair. See 1918.61(g).

• If a spreader is damaged and repaired, it must be retested before returning to service.
• Certificates documenting the test must be kept available as required in 1918.61(i).

Under 1918.61(h) all cargo handling gear with an SWL greater than five short tons must be proof load tested according to Table A every four years, and in accordance with the certification and accreditation rules in 1918.61(d) and (e). See 1918.61(h).

• Keep the proof test certificates and inspection records available for inspection per 1918.61(i).

Under 1918.61(i) certificates and inspection/test records that attest to the required tests and inspections must be available for inspection. See 1918.61(i).

• Maintain proof load certificates, initial test reports, retest reports after repairs, and inspection logs so they are readily available to inspectors.
• The standard does not specify a retention period here; retain records in line with company policy and other applicable requirements and make them available upon request.

Under 1918.61(f)(1) any special stevedoring gear that sustains damage requiring structural repair must be inspected and retested after the repair and before being returned to service. See 1918.61(f)(1).

• Retesting after repair ensures the repaired unit meets its original SWL and proof load criteria from Table A in 1918.61(f)(2).
• Use an OSHA‑accredited certifier as required by 1918.61(e).

Under 1918.61(b)(2) the standard requires that any employer‑provided cargo handling gear with an SWL over five short tons be plainly marked with that SWL; in practice this means the SWL must be durable and clearly legible to users. See 1918.61(b)(2).

• Common practical methods include stamping, etching, or affixing a durable metal nameplate or plate that resists wear and corrosion so the SWL remains readable during normal use.
• If markings become illegible, remove the gear from service until it is re‑marked following appropriate testing or manufacturer documentation.

Yes—OSHA guidance explains that hooks should be latched or otherwise secured to prevent accidental load disengagement where appropriate, and the longshoring standard 1918.66(e)(2) contains that requirement. See also OSHA's letter of interpretation on safety latches which explains when a safety latch is required and that industry standards (ASME/ANSI) recommend latch‑equipped hooks unless impractical: Safety latches on sling hooks.

• Use latch‑equipped hooks where the application makes latches practical to prevent slings or load parts from slipping off.
• If an application makes a latch impractical, document the reason and ensure other positive securing methods are used.

No — OSHA's interpretation makes clear an operator who becomes incapacitated or leaves the controls while a load is suspended may create an unsafe condition and the employer must ensure the assigned operator is physically able to perform the task without unscheduled interruption. See the crane operator medical condition scenario: Crane operator medical condition scenario and consider applicable longshoring rules such as 1918.66 that govern safe lifting operations.

• Employers should ensure operators are medically and physically fit for assignments and provide relief procedures that do not involve leaving a suspended load unattended.
• If an operator cannot complete a lift safely, the employer must have procedures (and trained personnel) to safely secure or land the load without exposing workers to hazards.

Under 1918.65 modifications that might affect a vehicle's capacity or safety must not be performed without the manufacturer's prior written approval or the written approval of a professional engineer experienced with the equipment; OSHA has advised that installing a strobe light is allowed if such approval is obtained. See 1918.65 and the OSHA interpretation on strobe lights: Strobe lights on industrial trucks.

• Obtain written approval from the manufacturer or a qualified engineer before installing accessories that could affect safe operation.
• Provide operator refresher training if the modification could affect how the vehicle is operated.

Under 1918.61 the testing rules distinguish spreaders and other non‑ship’s gear: spreaders used for intermodal containers that are not part of ship’s gear must be proof tested to 25% over rated capacity before initial use per 1918.61(g), whereas other special stevedoring gear follow the proof loads in Table A in 1918.61(f)(2).

• Check whether the spreader is part of ship’s gear; if not, apply the 1918.61(g) 25% proof test requirement.
• Maintain test certificates as required in 1918.61(i).

Under 1918.61(f)(2) gear with an SWL of five short tons or less may be inspected and tested as a unit before initial use in accordance with paragraphs (d) and (e) of this section or by a designated person, per 1918.61(f)(2).

• For initial unit tests you may use either an OSHA‑accredited certifier (per 1918.61(e)) or a designated person qualified by the employer to perform and document the inspection.
• For gear over five short tons, OSHA‑accredited certification is required for testing and periodic proof loads (1918.61(h)).

Under 1918.61(g) spreaders must be proof tested before initial use and after any structural repair, and under 1918.61(h) gear with SWL greater than five short tons must be proof load tested every four years in accordance with Table A; see 1918.61(g) and 1918.61(h).

• Initial proof testing, post‑repair testing, and four‑year interval testing (where applicable) are the principal occasions when proof loads are required.
• Ensure tests are performed and certified per 1918.61(e).

Under 1918.61(i) the employer must make certificates and inspection/test records available for inspection, so employers should retain dated certification documents, test reports, and inspection logs and store them where they are readily available. See 1918.61(i).

• Keep copies of OSHA‑accredited certifier certificates required by 1918.61(e).
• Maintain records after repairs and retests, and present them to inspectors when requested.