Overhead hoist requirements

The hoist must have the manufacturer's safe working load clearly indicated on it, and that load must never be exceeded. Employers and operators must follow the marking and the limit set by the manufacturer as required by 1926.554(a)(1).

• Check the hoist nameplate or data plate before each use for rated capacity.
• Do not rely on memory or rough estimates of weight—use load charts or scales.
• If a hoist’s rating is missing or unreadable, remove it from service until the rating is restored by the manufacturer or a qualified person.

(See also the general requirement to follow manufacturer-prescribed construction, testing, inspection, maintenance, and operation in 1926.554(a)(6).)

The supporting structure must have a safe working load equal to the hoist’s rated capacity. In other words, the support must be able to safely carry at least the same load the hoist is rated to lift as required by 1926.554(a)(2).

• Have a qualified engineer or competent person verify the support’s capacity when in doubt (for beams, anchors, roof supports, etc.).
• Include attachment hardware (shackles, bolts, welds) and the supporting structure in the load calculations.
• If temporary supports are used, document their rated capacity and the basis for that rating before lifting operations begin.

(Also follow the manufacturer’s installation and support instructions under 1926.554(a)(6).)

It means the support and attachment must allow the hoist to move and align itself with a load without restriction so the hoist can seat properly under the load, as required by 1926.554(a)(3).

• Free movement prevents side loading, binding, or off-center lifting that can overstress the hoist or supporting structure.
• Ensure trolley wheels, rails, or suspension points are unobstructed and aligned.
• Inspect for paint buildup, debris, or warped rails that could restrict movement and correct defects before use.

(Also consider manufacturer guidance on mounting and alignment under 1926.554(a)(6).)

The operator must position the hoist so they can stand clear of the load at all times—hoists must be installed in locations that permit the operator to remain out of the load’s path as required by 1926.554(a)(4).

• Design controls (station location, pendant cord length, remote controls) should ensure operators are not under or adjacent to suspended loads.
• Use remote or pendant controllers to increase separation when practical.
• If an operator must be near the load to guide it, use tag lines and have clear exclusion zones so no one stands under suspended loads.

(Refer to manufacturer installation and operation guidance under 1926.554(a)(6).)

Air hoists must be connected to an air supply with enough capacity and pressure to operate the hoist safely, and all air hoses must be positively connected so they cannot disconnect during use, per 1926.554(a)(5).

• Confirm the compressor or supply line provides the pressure and flow (cfm) the hoist manufacturer specifies.
• Use threaded, clamped, or quick-disconnect fittings designed to prevent accidental disconnection; avoid slip-fit or loose connections.
• Inspect hoses and fittings daily for wear, kinks, or damage; replace any worn or damaged components before use.

(Also follow the manufacturer’s instructions on air supply and hose connections under 1926.554(a)(6).)

Employers must ensure all overhead hoists meet the manufacturer’s applicable requirements for construction, design, installation, testing, inspection, maintenance, and operation, as stated in 1926.554(a)(6).

• Keep and follow the manufacturer’s manual for installation, load limits, inspection intervals, and maintenance procedures.
• Perform periodic inspections and tests to the schedule or checklist provided by the manufacturer; document findings and corrective actions.
• Only use replacement parts specified or approved by the manufacturer; unauthorized modifications can void ratings and create hazards.

(If the manufacturer’s instructions are unclear, consult a qualified person or the manufacturer for written clarification.)

If the hoist’s safe working load plate is missing or unreadable, take the hoist out of service until the manufacturer or a qualified person restores or verifies the rated capacity. This follows the requirement that the safe working load must be indicated and not exceeded in 1926.554(a)(1) and the requirement to follow manufacturer prescriptions in 1926.554(a)(6).

• Tag the hoist "Out of Service" and prevent its use until a competent person restores the rating or provides documentation of a verified capacity.
• Keep records of the verification or replacement nameplate on file.

(Do not attempt to guess capacity or modify the hoist to change capacity without manufacturer approval.)

A qualified or competent person should determine and verify that the supporting structure has the required safe working load and that the support arrangement allows free movement and proper alignment, as required by 1926.554(a)(2) and 1926.554(a)(3).

• Use engineering calculations or manufacturer documentation to establish capacity.
• A competent person should inspect rail alignment, hanger spacing, and attachments before lifting operations begin.
• Re-evaluate supports after any modification, damage, or unusual loading condition.

(Documentation of the verification helps show compliance with 1926.554(a)(6).)

No; operators must be able to stand clear of the load at all times, and overhead hoists must be installed so the operator is not required to ride on or be beneath the load, as required by 1926.554(a)(4).

• Riding on suspended loads creates a risk of falls and crush injuries and is inconsistent with the requirement to stand clear.
• If personnel transport is needed, use equipment specifically designed and certified for carrying people (and follow applicable scaffold or personnel hoist standards).

(If a conveyance or enclosure is used to carry people, see guidance about when conveyances are considered suspended scaffolds in OSHA’s interpretation on conveyances and suspended scaffolds: https://www.osha.gov/laws-regs/standardinterpretations/2023-12-05.)

Best practices are to use fittings and connectors designed to lock or be positively secured, inspect connections before each use, and replace worn hoses or fittings—because 1926.554(a)(5) requires that air hoses be positively connected to prevent disconnection during use.

• Use threaded fittings, safety clips, or locking quick-disconnects rated for the hoist’s pressure.
• Perform daily pre-use inspections for kinks, cuts, wear, and proper coupling engagement.
• Keep a documented maintenance log showing replacement or repair of hoses and fittings.

(Adhere to the hoist manufacturer’s specified hose type, pressure rating, and connection method under 1926.554(a)(6).)

No; employers should not perform modifications that change the hoist’s design or rated capacity unless the manufacturer or a qualified professional approves them, because 1926.554(a)(6) requires compliance with manufacturer-prescribed construction and design requirements.

• Unauthorized modifications can invalidate ratings and create hazards.
• If modification is necessary, obtain written approval or a stamped design from the manufacturer or a qualified engineer and document the change.
• Replace parts only with manufacturer-approved components or equivalent parts verified by a qualified person.

(Keep modification approvals and updated manuals with the hoist maintenance records.)

No; paragraph 1926.554(b) is reserved and contains no additional specific requirements.

• That means the general requirements in 1926.554(a) are the operative requirements in this section.

(Employers should still follow other applicable OSHA standards and manufacturer instructions where relevant.)

Yes; employers must assess workplace hazards and, when PPE is required for hoist operations, perform a hazard assessment and provide a written certification if PPE is required, consistent with the hazard assessment principles in OSHA’s PPE interpretation (https://www.osha.gov/laws-regs/standardinterpretations/2024-03-28) and the manufacturer-following requirement in 1926.554(a)(6).

• The hazard assessment should identify risks such as struck-by hazards, pinch points, electrical hazards, noise, or falling materials associated with hoist operations.
• Select PPE (gloves, hard hats, eye protection, hearing protection, fall protection if needed) based on that assessment and document the assessment per OSHA guidance.
• Train employees on PPE use and care, and provide PPE at no cost when required.

(See OSHA’s interpretation on hazard assessments for PPE: https://www.osha.gov/laws-regs/standardinterpretations/2024-03-28.)

When a conveyance or equipment is suspended by temporary cables, operates in temporary or incomplete guides, or uses a temporary hoist machine, OSHA may treat it as a suspended scaffold subject to scaffold fall protection requirements, as discussed in OSHA’s interpretation on conveyances and suspended scaffolds (https://www.osha.gov/laws-regs/standardinterpretations/2023-12-05) while also applying hoist general requirements in 1926.554.

• If a conveyance meets the suspended scaffold definition, fall protection must meet the scaffold standard requirements (e.g., guardrails, personal fall arrest systems) and falling object protections.
• Evaluate whether the device is a hoist used solely for material handling (covered under [1926.554]) or a conveyance carrying personnel or resembling a scaffold—if the latter, comply with suspended scaffold rules as interpreted by OSHA.

(See OSHA’s interpretation for examples and criteria: https://www.osha.gov/laws-regs/standardinterpretations/2023-12-05.)

Hoists should be inspected and maintained according to the schedule and procedures provided by the manufacturer, as required by 1926.554(a)(6).

• Follow the manufacturer’s recommended daily pre-use checks, periodic inspections, and preventive maintenance intervals.
• Document inspections, findings, repairs, and dates; remove defective hoists from service until repaired by qualified persons.
• If no manufacturer schedule exists, develop inspection and maintenance frequency based on usage, environment, and a qualified person’s guidance (e.g., daily visual checks and monthly functional inspections).

(Proper records help demonstrate compliance with 1926.554(a)(6).)

The employer is responsible for ensuring that all overhead hoists in use meet applicable manufacturer-prescribed requirements for construction, design, installation, testing, inspection, maintenance, and operation, per 1926.554(a)(6).

• Employers must provide resources and procedures for regular inspections, maintenance, and corrective actions.
• Employers should ensure only trained or qualified persons perform inspections, maintenance, and any repairs.
• Keep documentation of inspections, training, and maintenance to show compliance.

(Where additional hazards are present, follow other applicable OSHA standards and guidance.)

Before using a rented hoist, verify the hoist’s rated capacity is marked and legible, ensure the supporting structure meets the hoist’s rated load, confirm free movement and proper installation, verify the operator can stand clear, ensure air supply and hose connections meet requirements for air hoists (if applicable), and follow the manufacturer’s instructions—these are the combined duties in 1926.554(a)(1)–(6).

• Inspect the hoist on arrival for nameplate, damage, and missing parts; request the manufacturer’s manual or rental documentation.
• Confirm that temporary or existing supports are adequate for the hoist rating (engage a qualified person as needed).
• If pneumatic, confirm the rental provider supplied correct hose fittings or secure compatible positive connections.
• Record inspection and acceptance before first use and follow the rental company’s maintenance recommendations and manufacturer instructions.

(These steps implement the marking, support, movement, operator location, air supply, and manufacturer-following requirements of 1926.554.)

Controls include proper installation that allows free hoist movement and alignment, routine inspection of travel ways and trolleys, use of load guides or centering devices recommended by the manufacturer, and preventing obstructions—consistent with 1926.554(a)(3) and the requirement to follow manufacturer instructions in 1926.554(a)(6).

• Keep rails, wheels, and trolleys clean and lubricated per the manufacturer.
• Use tag lines to control the load during lifting if minor misalignment is possible.
• Train operators to position the hoist correctly and to stop operations if alignment issues arise.

(If you are unsure about a control, consult the manufacturer or a qualified engineer for corrective design changes.)

Employers must install hoists so operators can stand clear of the load at all times and ensure access and working areas are arranged to prevent employees from entering a load’s path, per 1926.554(a)(4).

• Establish exclusion zones under suspended loads with barriers, signage, or spotters.
• Provide remote controls or pendant stations placed so operators are not under loads.
• Train all nearby workers about hazards and keep nonessential personnel out of hazard areas during lifts.

(These measures implement the requirement that operators stand clear and support safe operation of overhead hoists.)

No; employers should use the hierarchy of controls—elimination, substitution, engineering, and administrative controls—before relying solely on PPE; PPE is a last line of defense. While 1926.554(a)(6) requires following manufacturer operation and safety measures, OSHA guidance on PPE hazard assessment (https://www.osha.gov/laws-regs/standardinterpretations/2024-03-28) emphasizes that employers must assess hazards and not rely solely on PPE.

• Implement engineering controls like positive barriers, remote controls, and mechanically interlocked guards where practical.
• Use administrative controls (procedures, training, exclusion zones) in addition to PPE.
• Provide appropriate PPE when hazards remain after other controls and document the hazard assessment.

(See OSHA’s hazard assessment interpretation: https://www.osha.gov/laws-regs/standardinterpretations/2024-03-28, and hoist manufacturer requirements in 1926.554(a)(6).)

Employers should keep records of hoist ratings/nameplate verification, engineering calculations for supporting structures, installation and alignment checks, inspection and maintenance logs, repair records, and manufacturer manuals or approvals to demonstrate compliance with 1926.554(a)(1)–(6).

• Maintain daily pre-use inspection checklists and periodic detailed inspection reports.
• Keep maintenance/repair invoices and parts records showing manufacturer-approved components.
• Retain any written approvals from manufacturers or qualified persons for modifications or support designs.

(These records support that you followed manufacturer requirements and the general hoist provisions in 1926.554.)