Crane / Lifting Plant
pre-use check

The 12 things to look at before the key turns on crane (mobile/tower), hiab / lorry loader.

Every item below says what good looks like, when it passes, the regulation or manufacturer's standard it rests on and the defects that usually fail it. That guidance is the difference between a tick and a check.

1. 1.

   Thorough examination certificate current
   What to look forOriginal (or controlled copy) of the LOLER reg.10 thorough examination report. Last exam date, next exam due, examiner name and qualifications, identity of equipment matching by serial/fleet number, statement of safe operating limits (SWL, configurations), defects schedule and any rectification deadlines.
   Acceptable when6-monthly if lifting persons; 12-monthly otherwise (or per scheme of examination). Cert in date. No outstanding "to be remedied within X" actions past their date. Equipment serial/configuration matches what is being used today.
   StandardLOLER 1998 reg.9, reg.10 and Schedule 1. BS 7121-2 (inspection, maintenance, thorough examination of cranes). HSE INDG422.
   Common defectsConfiguration on cert (e.g. main boom only) doesn't match today's rigging (with fly jib)Cert covers the carrier but not the supplementary hook block being usedDefect listed for rectification 4 weeks ago — no evidence of repair in the recordsCert from a foreign sister-company, not under a competent person recognised in the UKPhotocopy with no original signature — accept only with audit-trail documentation
2. 2.

   Visual check of wire ropes — no fraying or damage
   What to look forRun the rope slowly through the cab view (or with a banksman) over its full working length. Look for broken wires, "birdcaging", kinks, dog-legs, corrosion, lack of lubrication (dry-grey appearance), heat damage (blueing), and reduction in diameter. Pay particular attention to terminations (eye splice, swaged ferrule, wedge socket).
   Acceptable whenNo more than the discard criteria in BS ISO 4309 (e.g. for 6×36 IWRC: 5 broken wires in 6× rope diameter, 10 in 30×). No corrosion, no kink, no heat damage. Diameter reduction <7% of nominal. Terminations to manufacturer spec (wedge oriented dead-end down, etc.).
   StandardBS ISO 4309 (wire rope discard criteria). LOLER 1998 reg.7. BS 7121-2.
   Common defectsLocalised cluster of broken wires at a fixed termination — high-stress zone, discardBirdcaging where the rope was shock-loaded — internal damage, not always visibleWedge socket installed upside down — dead-end takes the load, not the liveDry rope with surface rust — overdue for lubrication, accelerated wearDiameter reduction at the drum lay — internal core collapse
3. 3.

   Hook and safety catch in good condition
   What to look forHook body free of cracks, distortion, or twist. Safety catch (mousing) springs closed positively against the hook tip without binding. Throat opening within manufacturer's reject limit (typically 10–15% over nominal = discard). Wear at the saddle (seat) within tolerance. Identification mark, SWL, and serial visible.
   Acceptable whenNo cracks (NDT confirmed at LOLER exam). Throat opening within 10% (or per maker's gauge). Catch closes fully and returns under spring. Twist <10° from plane. SWL plate legible.
   StandardBS EN 1677 (forged steel components for slings). LOLER 1998 reg.7. Manufacturer's reject criteria.
   Common defectsSafety catch missing or wired open ("for speed")Throat stretched from a snatch lift — over the 10% limit, discardHook seat worn flat where slings sit — point loads concentrate on the bendCatch spring corroded and slow to return — debris jams it openTwist visible from a side-loaded lift — bin it, don't straighten
4. 4.

   Load indicator / SLI functioning
   What to look forBoot the SLI/RCI/RCL through its self-test sequence. Display lights all segments, length and angle sensors live, configuration matches the rigging (boom length, fly jib in/out, counterweight, outrigger spread). Audible and visual pre-warning at 90%, cut-off at 100% (lockout test on a known load if shift requires).
   Acceptable whenPre-warning at 90% rated capacity (visual + audible). Function lockout at 100%. Configuration in the SLI matches the actual rigging. Calibration sticker in date (typically 12 months).
   StandardBS 7121-2. LOLER 1998 reg.7. EN 13000 (mobile crane safety). Manufacturer's commissioning spec.
   Common defectsConfiguration set wrong (counterweight selected as fitted but it isn't) — false high capacityLength sensor cable damaged — readings frozen, machine looks underloadedOverride key left in or taped on — bypass fitted, critical defectPre-warning at 95% not 90% — calibration drift, due for serviceAudible alarm muted by buzzer disconnect — visual only, easy to miss in cab noise
5. 5.

   Outriggers / stabilisers operational
   What to look forEach outrigger extends to the position selected (full, intermediate, retracted) and the SLI registers the same. Pads firm onto firm ground, no air gap; spreader mats in place where ground bearing pressure dictates. Locking pins engaged. Hydraulic creep check — leave on the pads for 5 mins and confirm no settling.
   Acceptable whenAll four (or as fitted) at the selected position with positive locking. SLI agrees with operator selection. No creep down on the pad over 5 mins. Mats sized per supplier ground-pressure calc — pad never to be on softened ground without a mat.
   StandardBS 7121-1 / BS 7121-3 (mobile cranes, lorry loaders). LOLER 1998 reg.4 (positioning). CDM 2015 reg.27. Manufacturer's ground bearing pressure data.
   Common defectsOutrigger creeps in over 30 minutes — leaking pilot-operated check valveSelected position not what the SLI shows — limit switch out of adjustmentMat too small for the pad pressure — point loading, ground failure riskPad set on a backfilled service trench — undisclosed weak groundLocking pin missing or replaced with a bolt — non-compliant repair
6. 6.

   Slew, hoist, luff controls checked
   What to look forNo load, slow movements first. Slew left and right, brake holds on release. Hoist up and down — drum spools evenly, no jerks. Luff up and down — smooth, brake holds. All controls return to neutral cleanly. No unusual noise (whine = pump, knock = brake, squeal = rope on a worn sheave).
   Acceptable whenSmooth proportional control. Brakes hold the motion immediately on release. Self-centring of all levers/joysticks. No abnormal noise or vibration. Drum spooling tight and even.
   StandardBS 7121-2. LOLER 1998 reg.7. PUWER 1998 reg.14, reg.17. Manufacturer's function check.
   Common defectsSlew brake fade — drift on release, especially after warm-upHoist drum with overlapping wraps — rope crushed at the next layerLuff cylinder weeping — slow drift down with load, replace sealsWhine on hoist up — pump cavitating, low fluid or blocked suctionJoystick sticky off centre — gimbal wear, repeat slow corrective inputs
7. 7.

   Limit switches functioning
   What to look forTest (slowly, no load): anti-two-block (hook block to head sheave) cuts hoist-up; hoist-down stops before drum unwinds beyond minimum dead wraps; luff-up and luff-down end stops trigger. Slewing limit (where fitted, e.g. tower cranes) operates. Visual indication on the SLI when each limit triggers.
   Acceptable whenAll limits trigger before hard mechanical stop. Anti-two-block weight present and free, switch resets when block lowered. Min dead wraps (typically 3) maintained at hoist-down limit. Reset only by intended override per procedure.
   StandardBS 7121-2. EN 13000. LOLER 1998 reg.7. ASME B30.5 anti-two-block where applicable.
   Common defectsAnti-two-block weight tied up "to stop it banging" — limit defeatedLimit switch electrically connected but mechanically jammed — no actual cut-offHoist-down limit set so low that fewer than 3 dead wraps remainOverride button taped on — limits permanently bypassedSlew limit sensor knocked off alignment by a previous trailer load
8. 8.

   Ground conditions suitable
   What to look forMatch the actual ground bearing capacity to the calculated pad pressure for the worst-case lift. Check for recent excavation/backfill, services, basements, slabs of unknown thickness, frost, saturation. Slope under the carrier within manufacturer's spec (typically <1°). Mats sized per the lift study.
   Acceptable whenGround bearing pressure (kPa) under each pad ≤ allowable for the soil/slab. Confirmed by an appointed person's lift plan. Carrier level within spec. Mats sized correctly and in good condition (no rotted laminations).
   StandardBS 7121-3 (mobile crane safe use). CDM 2015 reg.27. CIRIA C703 / SP123 ground guidance for plant.
   Common defectsPad on tarmac over a known service run — no spreader, slab failure riskMats taped together that are too short for the load spanGround saturated after rain since the lift plan was written — recalc neededSlope under carrier exceeds spec — corrected with hardcore by the operator, not the APHidden basement under the lift — building drawings not consulted
9. 9.

   Wind speed within operational limits
   What to look forRead the cab anemometer at boom-tip height (or use the site weather station, corrected for height). Compare against the manufacturer's wind chart for the boom length, jib config, and load shape (sail area). Forecast for the duration of the lift, not just now.
   Acceptable whenMean wind speed below the manufacturer's out-of-service or in-service limit (typically 9.8–14 m/s in service for many mobile cranes; less for tower cranes and large sail-area loads). Gust margin observed. Stop work and travel to safe configuration before limit reached, not at it.
   StandardBS 7121-1. EN 13000 / EN 14439. Manufacturer's wind chart. Met Office forecast for the shift.
   Common defectsAnemometer reading not corrected for boom-tip height (ground readings underestimate)Sail area of the load not considered (e.g. a wall panel acts like a kite)In-service limit confused with out-of-service stowage limitGusts exceed the chart even though the mean is OKAnemometer cable damaged — display reading 0 when it shouldn't be
10. 10.

    Exclusion zone established
    What to look forPhysical barriers (Heras, A-frame, banksman cordon) covering the full slewing radius plus the reach of any potential dropped load. Signed "Do not enter — lift in progress". Banksman positioned, in eye contact with the operator, with radio comms checked. Adjacent works paused or relocated for the duration.
    Acceptable whenBarrier covers max boom slew radius + dropped-load envelope. No personnel inside the zone except the lift team. Comms working both ways. All adjacent operatives briefed.
    StandardCDM 2015 reg.27. BS 7121-1. HSG144 traffic management. Lift plan / appointed person's exclusion drawing.
    Common defectsTape/bunting only — non-physical, easily ignoredZone sized for the load but not for slew tail swing of the counterweightBanksman with no line of sight — relying on radio only without backup signalAdjacent trade pushed through the zone "for two minutes"Public footpath running through the zone, not closed
11. 11.

    Lift plan available for complex lifts
    What to look forWritten lift plan signed by the appointed person, accessible to the lift team and operator. Includes: load weight (with tolerance), centre of gravity, lift configuration (boom/jib/counterweight), radius, ground bearing, slinging arrangement, exclusion zone, contingency, sequence. Not just a generic risk assessment.
    Acceptable whenPlan covers this specific lift in this configuration on this ground. AP signature present. Operator and slinger have read and signed. Contingency for crane breakdown / emergency lower documented.
    StandardBS 7121-1 (categorisation: basic / standard / complex). LOLER 1998 reg.8. CDM 2015 reg.13.
    Common defectsGeneric plan from a previous job copied without recalculating GBPLoad weight stated as "approx" without tolerance — unknown overload marginNo sketch of slinging — left to the slinger on the dayAP signature missing — plan never formally issuedPlan in date but the rigging on site doesn't match (e.g. fly jib not deployed)
12. 12.

    Operator card valid (CPCS/NPORS)
    What to look forOperator photo card matches the person. Endorsement covers the specific machine class (e.g. CPCS A60 for mobile crane, A61 for crawler, A04 for lorry loader). In date. Logbook completed for trained-operator (red) cards. Verifiable on the scheme app where possible.
    Acceptable whenIn-date scheme card for the correct category. Photo matches. Trained operators supervised and logged. Operator familiar with this specific make/model (familiarisation check on hire).
    StandardCDM 2015 reg.15. PUWER 1998 reg.9. BS 7121-1. Build UK / MCG card requirements.
    Common defectsWrong category (A04 lorry loader presented for an A60 mobile crane lift)Card in date but no familiarisation on this make/model — lift profile unfamiliarRed trained operator card with the supervisor signed off as the operator themselvesCard photocopy presented — original required on siteCard expired in the last week — operator unaware

Questions people ask