Six Findings at the Morning Briefing
You are the lift director for a 90-ton all-terrain crane scheduled to set a 14,000 lb chiller at a 55 ft radius, where the chart shows 18,000 lb. At the morning briefing you find: the annual comprehensive inspection sticker is dated 13 months ago; the monthly inspection sheets for the past two months are blank; the crane was assembled at this site three days ago by the operator and a helper, and no post-assembly inspection record exists; the load chart in the cab is for a 70-ton model, and the correct chart is in the site office; the operator's NCCCO card expired two months ago, though he has 20 years of experience; and the anti-two-block device is taped over because it 'keeps false-alarming.' The GC wants the chiller set before the roofers arrive at 10 a.m.
1. List each finding, state whether it stops the lift, and cite the controlling requirement.
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Findings and disposition
- Annual inspection 13 months old - STOP. Section 1926.1412 requires a comprehensive annual inspection by a qualified person at least every 12 months. The crane is out of service until it is done and deficiencies are corrected.
- Monthly inspections blank - STOP. Monthly inspections are required and must be documented. Complete them and correct any deficiencies before use.
- No post-assembly inspection - STOP. After assembly at a new location, the crane must be inspected by a qualified person before use (1926.1412). The operator and helper assembling it does not satisfy the inspection requirement.
- Wrong load chart in the cab - STOP. The operator must have the manufacturer's load chart for the crane's actual configuration. A 70-ton chart on a 90-ton crane is a capacity-verification failure.
- Expired operator certification - STOP. Section 1926.1427 requires the operator to be certified for the crane type. Twenty years of experience does not substitute for a current certification.
- Anti-two-block disabled - STOP. Section 1926.1416 requires operational aids to function. Taping over the device is a prohibited alteration.
Also, 14,000 / 18,000 = 78%, so under a typical 75% threshold this is a critical lift and needs a critical-lift plan. The lift does not proceed today.
2. Who is allowed to perform the annual comprehensive inspection, and can the site mechanic do it?
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The annual comprehensive inspection must be performed by a qualified person - someone who, by training, experience, and knowledge of the crane type, can identify hazards and defects. The employer must be able to show that the person meets that definition.
A site mechanic is not automatically qualified. The question is whether the mechanic has the training and crane-specific knowledge for this 90-ton all-terrain crane and can inspect the items in the manufacturer's manual, including structural members, wire rope, brakes, clutches, operational aids, and safety devices. If the mechanic cannot document that, use a third-party inspector or the manufacturer's service organization.
The inspection must be documented, and any deficiency that affects safe operation must be corrected before the crane is returned to service. The lift director should not accept a verbal 'it looks fine.'
3. What is the minimum documentation package for this lift, and who signs off on each part?
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Minimum package on site before the pick:
- Lift plan, including a critical-lift plan at 78% of chart, with the crane configuration, radius, boom length, load weight, rigging, and ground conditions.
- Load chart for the actual crane and configuration.
- Rigging plan and rigging capacity documentation.
- Ground/outrigger assessment, including underground utilities and mat sizing.
- Inspection records: annual, monthly, and post-assembly.
- Operator certification current for the crane type; signal person qualification.
- Pre-lift meeting record with the crew.
- Permits and utility clearances, plus the site-specific safety plan.
Sign-off: the lift director approves the plan and the pre-lift conditions; the employer/crane owner is responsible for inspections and certification; the operator and rigger verify their equipment. The lift director has stop-work authority and should use it. Nothing in the package is optional because the roofers are coming at 10 a.m.