Pre-Operational Inspection, Setup and Stability
Before every shift
A pre-start inspection is a documented check, not a glance. Walk the machine and check: structure for cracks or deformation, particularly at portal legs, welds and the boom; ropes for broken wires, kinks, corrosion and correct reeving; hooks for throat opening, wear and latch function; brakes and clutches; limiters and indicators (test function where permitted); warning devices; fluid levels; and the condition of rails, clamps, wheels or outriggers. Record defects and tag out anything unsafe.
Setup and stability
For a portal crane, setup means verifying the track or foundation: rail alignment, gauge, level, sleeper condition, clearances and end stops. For outrigger-equipped variants, check ground bearing capacity, pad condition and full extension. Stability depends on level ground, correct ballast/counterweight, and keeping the load moment within the chart. Traps include assuming a level-looking surface is load-bearing, ignoring wind restrictions after setup, and skipping the limiter test because "it worked yesterday".
Exclusion zones and access
Establish the slew and travel exclusion zone before operation, confirm access ladders and platforms are secure, and check that no one is in the portal area before moving.
Worked rule of thumb
Use the "walk, test, record, tag" sequence: walk the full machine, test critical safety devices, record results, and tag out any defect that affects safe capacity. If a safety device is faulty, the crane is out of service until repaired - do not compensate manually.