NCCCO Crane Inspector flashcards

32 cards. Read the term and the definition here. The deck at the top of this page is optional.

Wire rope broken wire limit

For running wire rope, remove from service when 12 randomly distributed broken wires are found in 6 rope diameters, or 4 broken wires in one strand in 6 diameters, or 6 broken wires in 30 diameters.

Sheave groove wear limit

A running rope sheave must be replaced when the groove diameter exceeds the nominal rope diameter by more than 5 percent, or when the flange thickness is less than 50 percent of original.

Hook throat opening limit

Remove a hook from service when the throat opening has increased more than 15 percent of its original dimension, when wear exceeds 10 percent of the original cross-section, or when twist exceeds 10 degrees.

Chain sling wear limit

Remove a chain sling when link stock wear exceeds 15 percent of the original diameter or when the chain has stretched more than 5 percent of its original length; also remove for cracks or bent links.

Anti-two-block device

A safety device that prevents the load block from contacting the boom tip; it must be functional and tested each shift, and a non-functioning device is a removal-from-service condition.

Structural weld crack

A crack in a primary load-bearing weld, such as at the boom pivot or turntable, is a removal-from-service condition until repaired per the manufacturer or a qualified engineer and re-inspected.

Outrigger beam inspection

Verify outrigger beams extend and lock, pads and floats are not cracked or deformed, and welds are sound; cracked welds or bent beams require removal from service until repaired and re-inspected.

Hydraulic hose leak

A leaking hydraulic hose on a load-holding circuit is a removal-from-service condition because it can allow an uncontrolled load drop; inspect for abrasion, blistering, and leaks each shift.

Load moment formula

Load Moment equals Load Weight multiplied by Load Radius. The load moment plus the machine moment must remain within the crane's rated capacity at that radius for the configuration in use.

Rated capacity definition

The maximum load the crane is designed to lift at a given radius and configuration, determined as the lower of the structural limit and the stability limit, and published in the load chart.

Net capacity calculation

Net capacity equals the gross capacity from the load chart minus the weight of all lifting attachments, including the hook block, slings, spreader bar, and any below-the-hook device.

Tandem lift capacity rule

In a two-crane lift, each crane's share of the load must not exceed 75 percent of its rated capacity at the working radius unless the lift is engineered and approved, and the load must stay within combined stability.

Personnel lifting requirements

Personnel may be lifted only with a crane and platform designed and approved for personnel, with a pre-lift meeting, a trial lift, fall protection, a platform gate, and maintained communication with the operator.

Wind speed limit

The manufacturer's load chart wind limit governs, often 20 mph or less for large booms; when wind exceeds the limit, stop the lift and lower or secure the boom per the manufacturer's instructions.

Outrigger float pressure

Float pressure equals the total crane plus load weight divided by the total float bearing area; verify the supporting surface has adequate bearing capacity before setup to prevent settlement or tipping.

Signal person requirement

A signal person is required when the operator cannot see the load or load path; only one signal person may direct the operator at a time, using hand signals, voice, or radio per ASME B30.5.

Load chart verification

The load chart in the cab must match the crane model, boom configuration, and outrigger configuration; a missing or mismatched chart is a removal-from-service condition until corrected.

Annual inspection requirement

ASME B30.5 and OSHA 1926.1412 require a documented annual inspection by a qualified person covering structural, mechanical, electrical, and hydraulic components, with records retained and available.

Frequent inspection interval

A frequent inspection is required monthly to quarterly depending on severity of use, covering items in the manufacturer's manual and ASME B30.5, with written records of findings and corrective actions.

Periodic inspection interval

A periodic inspection is required annually to biennially depending on severity of use, including disassembly of components as needed to inspect for wear, cracks, and hidden damage.

Pre-shift inspection

The operator must perform and document a pre-shift inspection each shift, checking controls, brakes, limit switches, and safety devices before use, per ASME B30.5 and OSHA requirements.

OSHA wire rope inspection

OSHA 29 CFR 1926.1413 requires wire rope inspections at specified intervals, and 1926.1412 requires annual and periodic inspections by a qualified person, with records available for review.

Proof load test certificate

Verify the crane has a current load test certificate where required by the jurisdiction, and that the test was performed at the rated capacity or as specified, with results documented and retained.

Operator certification check

Verify the operator holds a valid certification, such as NCCCO, for the crane type being operated, and that the inspector is a qualified person as defined by ASME B30.5 and OSHA.

Safety equipment verification

Verify the crane is equipped with a fire extinguisher, seat belt, and safe access ladders and steps per OSHA 1926.1411 and 1926.1412, and that all safety devices are functional.

Inspection report content

A report must include crane make, model, serial number, hour meter reading, date, inspector name and qualification, items inspected, findings, and corrective actions with target dates.

Deficiency classification

Classify findings as removal from service, repair before next use, monitor at next inspection, or no action; the classification drives disposition and re-inspection interval.

Inspection record retention

Retain inspection records per the manufacturer's manual and applicable regulations; OSHA requires records to be available for the duration specified, commonly the current and prior inspection cycle.

Non-destructive testing

When cracks are suspected in critical welds or pins, require magnetic particle or dye penetrant testing by a qualified NDT technician, and document the test method and results.

Post-repair re-inspection

After any structural repair, the crane must be re-inspected and, where required, re-tested to the original rated capacity before return to service, with results documented.

Load test documentation

Record test load weight, radius, configuration, and results; a load test certificate must be signed by the person conducting the test and retained with the crane records.

Corrective action tracking

Each deficiency must have an assigned responsible person, a due date, and verification of completion; open removal-from-service items must be locked out and tagged until cleared.