Crane Preventive Maintenance

Crane preventive maintenance best practices and resources help ensure your equipment stays safe for use, compliant, and productive throughout its service life. 

If you are a crane owner, operator, employer, or other related industry member involved in the maintenance and upkeep of cranes, it is important that you understand your responsibilities and the requirements to build and implement an effective preventive maintenance and inspection system. 

You can use our tools and checklists to create a comprehensive program that meets British Columbia’s regulations and standards for mobile, tower, and other regulated cranes.

What is Preventive Maintenance

Preventive maintenance is planned regular maintenance of the equipment, as prescribed by the original equipment manufacturer, regulatory direction, relevant standards from the Canadian Standards Association (CSA), and good engineering practice.

The goal is to reduce the likelihood of equipment failure and to prevent unplanned equipment downtime.

Why Preventive Maintenance Matters

Cranes can only perform lifts safely if the equipment is in good operating condition.

A lack of attention to basic maintenance and repair has been a factor in many serious crane accidents.

Regular inspections and preventive maintenance are critical to:

• Identifying hazards before they cause incidents.
  Worn, corroded, or damaged components can lead to loss of control, dropped loads, or structural failure if not found early.
• Confirming that cranes are safe to operate.
  Inspections verify that critical systems such as brakes, limiters, structural members, and wire rope can still carry out their original design function with an adequate margin of safety.
• Preventing costly downtime and delays.
  Routine inspections catch issues before they become large, complex repairs that take the crane out of service.
• Demonstrating due diligence.
  Complete and consistent inspection and maintenance records can be vital in investigations, contractual disputes, or injury claims.

Mobile Crane Failures: Why Maintenance and Inspections Are Critical

Inspection Frequencies and Types

A compliant preventive maintenance system combines frequent and periodic inspections.

The exact schedule must follow the OEM instructions, OHSR, and relevant CSA standards, but typical expectations include:

Frequent Inspections (Function & Condition Checks)

• Pre‑Use, Pre‑Shift and Daily
  Visual and functional checks completed by the operator.
• Weekly and Monthly
  More detailed checks of safety devices, wire rope, and other critical components.

These frequent inspections focus on issues that can change quickly with day‑to‑day use, such as:

• Wire rope condition (broken wires, bird caging, corrosion, kinks)
• Hydraulic leaks and hose condition
• Loose, missing, or corroded bolts and pins (including tie‑in and base connections on tower cranes)
• Brakes, limit switches, and other safety devices
• Warning lights, horns, and load indicators

Periodic and Annual Inspections
Periodic inspections may be monthly, quarterly, annual, five‑year, or ten‑year, depending on the equipment and standard. These are more comprehensive and may require:

• Partial or full disassembly and cleaning (e.g., boom, slewing ring, load block)
• Nondestructive testing (NDT) such as magnetic particle, liquid penetrant, or ultrasonic tests
• Detailed inspection of:
  • Major structural components (mast sections, slewing ring, tie‑ins, booms, etc.)
  • Mechanical systems (gearboxes, drums, brakes, bearings, etc.)
  • Electrical and control systems (limiters, zoning/anti‑collision, load moment indicators (LMIs), remotes, etc.)

For tower cranes, BC Crane Safety’s Inspection and Maintenance of Tower Crane Major Components guidance recommends periodic teardown and detailed inspection of items such as the slewing ring, slew ring fasteners, load hook assembly, hydraulic systems, gearboxes, drums, bearings, and safety devices, with documentation of when and by whom each inspection is conducted.

The Core Elements of a Crane Preventive Maintenance Program

A robust program typically includes the following building blocks:

1. Clear Roles, Responsibilities, and Continuous Improvement
2. Equipment Logbooks and Records
3. Major Components and Systems

1. Clear Roles, Responsibilities, and Continuous Improvement
   BC Crane Safety’s Level Up, Own Your Lift Self-Planned Inspections framework outlines the responsibilities of all parties involved in crane inspection and preventive maintenance.
   It also supports continuous improvement using a structured Plan–Do–Check–Act (PDCA) approach.

   Crane Owners and Employers should:

   • Establish and resource a documented preventive maintenance system for every crane in the fleet.
   • Designate a qualified person to oversee crane maintenance and repair activities.
   • Maintain comprehensive owner’s logbooks and records, including inspection results, maintenance history, repairs, modifications, and certifications.
   • Ensure cranes are inspected, tested, and maintained in accordance with OEM instructions, OHSR requirements, and applicable CSA standards (e.g. Z150, Z248).

   Maintenance Supervisors should:

   • Define and document their role, responsibilities, and qualifications within the maintenance system.
   • Ensure workers performing inspections and repairs are trained, competent, and properly supervised.
   • Maintain systems for recording modifications, NDT results, repairs, structural assessments, and other maintenance actions.
   • Verify that logbook entries capture dates, names, and detailed descriptions of all inspection, maintenance, and repair activities.

   Crane Operators & Site Supervisors should:

   • Conduct pre use and daily inspections and document findings accurately in the crane logbook.
   • Report defects promptly and ensure equipment is removed from service when conditions could endanger workers.
   • Participate in toolbox talks, refresher training, and site-specific preventive maintenance procedures.

   The Level Up, Own Your Lift process helps employers evaluate and strengthen their preventive maintenance and inspection systems for continuous improvement.

   The included question sets support improvement in areas such as:

   • Employer and site-level inspection systems
   • Preventive maintenance practices
   • Crane maintenance documentation
   • Component specific inspection systems (e.g., fixed wire ropes, high tensile bolts)

   Employers and site representatives are encouraged to identify 1–2 actionable improvements (e.g., updating checklists, improving training, closing documentation gaps) and then reassess to confirm whether risk has been reduced.

2. Equipment Logbooks and Records
   An effective preventive maintenance system depends on accurate, accessible records.
   BC Crane Safety’s Toolbox Talk: Equipment Logbooks emphasizes that:
   • Each crane or piece of equipment should have its own logbook, which stays with the machine.
   • A logbook should include:
     • General information (manufacturer, model, serial number, location, person responsible)
     • Maintenance actions (date, description, and person performing each action)
     • Remarks (notes on defects, wear, and follow-up needs)

   Logbooks should capture all the following, as applicable:

   • Operator certifications
   • Daily pre-use inspections
   • Weekly and monthly inspection results
   • Annual inspections and stability tests
   • Safety device inspections and tests
   • Auto lift / self-erect functions (where applicable)
   • Maintenance, repairs, and modifications
   • Certificates and engineering reports

   These records are essential for:

   • Demonstrating due diligence.
   • Supporting annual engineering certifications.
   • Providing evidence in case of incidents or disputes.
3. Major Components and Systems
   Your preventive maintenance program should explicitly address major crane systems and how they are inspected, maintained, and documented, including:
   • Structural components (tower sections, bases, tie-ins, jib/boom, slew ring, welds, anchorage, and foundations)
   • Mechanical systems (winches, gearboxes, brakes, slewing gear, sheaves, drums, and hydraulic systems)
   • Electrical and controls (control panels, wiring, LMIs, limit switches, anti-collision and zoning systems, and operator aids)
   • Lifting components (hooks, blocks, slings, wire rope, and terminations)
   • Temporary and auxiliary devices on cranes (tower crane signage, task lighting, aeronautical lights, access platforms, hoarding, cameras, limit-of-approach markers, etc.)

   BC Crane Safety’s Safe Work Practice: Inspecting Tower Crane Temporary Devices provides a simple site-ready checklist to confirm that temporary devices attached to a tower crane are secure, functional, clearly marked, and not creating tripping or collision hazards.

The Importance of Training

Effective preventive maintenance relies on workers who are properly trained, competent, and using accurate, equipment specific information. Manufacturer (OEM) training is strongly advised, as OEM instruction provides the most reliable guidance on inspection procedures, service intervals, component tolerances, and updates that may affect safe operation.

Employers should also maintain a structured internal training program that reinforces:

• Equipment specific procedures aligned with the OEM manual and service bulletins
• How to identify, report, and document defects
• Safe use and testing of safety devices (limit switches, LMIs, anticollision systems, etc.)
• Proper completion of logbooks and maintenance records

Here are some Occupational Health and Safety Regulation (OHSR) requirements related to training and recordkeeping:

• OHSR Part 3, Section 3.23–3.25
  Employers must provide instruction and training necessary to ensure worker health and safety.
• OHSR Part 4, Section 4.3 Safe Machinery and Equipment
  Employers must ensure workers who operate or maintain equipment are adequately trained and instructed and follow the manufacturer’s instructions.
• OHSR Part 14, Section 14.13(4)
  Crane maintenance and repairs must be performed by or under the direct supervision of a qualified person.
• OHSR Part 14, Section 14.14 Inspection and Maintenance Records
  Inspection and maintenance records must be kept; this reinforces the need for workers trained to document their work accurately.

Together, OEM training, internal competency development, and proper training records help employers meet their regulatory duties and maintain safe, reliable crane operations.

Annual Inspection and Certification

In B.C., many cranes and related lifting devices require annual inspection and certification by an engineering professional.

The Engineers and Geoscientists BC Professional Practice Guidelines: Annual Equipment Inspection and Certification in British Columbia outlines the standard of practice for:

• Developing an inspection plan
  Structural, mechanical, and controls based on:
  • OEM manuals, bulletins, and recommendations
  • OHSR requirements
  • Applicable CSA/ASME standards
  • The crane’s age, hours, service conditions, and history
• Coordinating and scheduling
  • Annual mechanical and controls inspection
  • Annual structural inspection and any required NDT
  • Repair instructions and verification of repairs
• Issuing “Safe for Use” certifications
  Using standardized forms that clearly state:
  • What was inspected and to what standard
  • Which components (if any) are excluded
  • The validity period of the certification

Preventive maintenance and accurate record‑keeping make the annual certification process more efficient, transparent, and defensible for owners, engineers, and WorkSafeBC.

B.C. Regulatory Framework for Inspection and Maintenance

Crane inspection and preventive maintenance in B.C. must comply with Occupational Health & Safety Regulation (OHSR) and relevant standards and guidance.

Occupational Health & Safety Regulation
WorkSafeBC’s Occupational Health and Safety Regulation include important requirements related to crane preventive maintenance. Listed here are relevant sections of interest.

These sections require cranes to be inspected and maintained at a frequency, and to the extent necessary, to ensure components can carry out their design function with an adequate margin of safety, and that records are kept and available at the workplace.

OHSR Part 3 Workplace Inspections
Section 3.5 Workplace Inspection Requirements

OHSR Part 4 General Conditions
Section 4.3 Safe Machinery and Equipment
Section 4.9 Inspection and Maintenance Records

OHSR Part 14 Cranes and Hoists
Section 14.12 Manual and Instructions
Section 14.13 Inspection, Maintenance and Repair
Section 14.14 Inspection and Maintenance Records
Section 14.35 Pre-Use Inspection
Section 14.71 Annual Inspection
Section 14.79 Manuals and Records

Applicable Standards and Guidance
Depending on crane type and use, the following standards and guidance may apply:

• CSA Z150 Safety Code for Mobile Cranes
• CSA Z248 Code for Tower Cranes
• ASME B30 Series Standards
• OHSR Part 14, Section 14.2 Standards

In B.C., WorkSafeBC regulations use the following referenced standards:

• CSA Standard Z150-1998 Safety Code for Mobile Cranes
• CSA Standard Z248-2004 Code for Tower Cranes

Additional Resources

BC Crane Safety provides a range of tools, toolbox talks, checklists, and reference materials to support day‑to‑day implementation of crane preventive maintenance programs.

These resources help reinforce inspection fundamentals, improve record‑keeping, and strengthen workplace maintenance systems.

Use these resources for:

• Consistent application of preventive maintenance practices.
• Strengthening of maintenance and inspection culture.
• Increasing crew level understanding of key inspection and recordkeeping principles.
• Early detection and reporting of defects.
• Compliance with OHSR requirements and applicable CSA standards.

Toolbox Talks
Inspections Refresher
Wire Rope
Equipment Logbooks
Preventive Maintenance

Safe Work Practices
Regular Inspection Requirements for Cranes
Inspection and Maintenance of Tower Crane Major Components
Inspecting Tower Crane Temporary Devices

Preventive Maintenance & System Improvement Tools
Level Up, Own Your Lift: Preventive Maintenance Questions

Engineering and Certification Resources
Engineers & Geoscientists British Columbia: Annual Equipment Inspection and Certification in British Columbia