Overhead, Gantry and Jib Crane Inspection with Runway Assessment

Overhead cranes are the most-used and least-inspected lifting equipment on most sites. They run continuously and are rarely visible from the floor, and the structure that carries them, the runway beams and their supports, is part of the building and not of the crane, so it often falls outside both the crane inspection and the building inspection. itmad inspects overhead, gantry and jib cranes together with their runways, at the client's facility. itmad operates across the Middle East, Asia and Europe. Last reviewed: October 2026.

Equipment covered

The range includes electric overhead travelling (EOT) cranes, single and double girder, under-slung and top-running cranes, goliath and semi-goliath gantry cranes, portal and semi-portal cranes, jib and pillar cranes, wall-mounted and slewing jib cranes, monorail and beam trolley systems, workshop and maintenance cranes, and process and ladle cranes.

Runway beams and supporting structure

This is where the significant findings usually are, and it is the part most often omitted. Runway beams carry the full crane and load reaction into the building, and a beam that has been modified, drilled or had services hung from it is no longer the beam that the crane was designed for. itmad examines runway beams for cracking at welds and connections, distortion and corrosion, checks beam-to-column and beam-to-support connections for bolt condition and tightness, and inspects the rails for wear, alignment, level, gauge and joint condition, together with their fixings and clips along the full length.

End stops and buffers must be present, secure and adequate for the crane's mass and speed. The inspector looks for evidence of unauthorised modification, drilling or attachment to the runway structure, and measures deflection under load where the condition or history of the runway warrants it.

Bridge, end carriages and travel

Bridge girders are examined for cracking, distortion, camber loss and corrosion. End carriage structure, wheel condition, flange wear and axle bearings are checked, together with wheel alignment and skewing, which drives rail and flange wear. Long travel and cross travel drives, gearboxes and couplings are examined, travel brakes are tested for stopping distance and holding, and anti-collision devices and travel limit switches are function tested. Down-shop conductor bars, festoon systems and cable reels complete the checks.

Hoist, rope and hook

The hoist mechanism, gearbox, couplings and drive are examined, and the hoist brake and load-holding brake are tested for holding capability under load and not merely observed to release. Wire rope is assessed against ISO 4309 discard criteria, or load chain against the manufacturer's stretch and wear limits, and drum condition, grooving, spooling, minimum dead turns and rope anchoring are checked, along with sheaves, reeving and rope guards. Hooks are examined for throat opening, twist, wear and cracking, with magnetic particle inspection where the condition or standard requires it, and the safety latch, swivel and block assembly are checked, as are the upper and lower hoist limit switches, including the secondary limit where fitted.

Controls and safety devices

Pendant, radio remote or cab controls are tested, including the deadman and emergency stop. Overload protection and load display are verified against known loads and not assumed, and isolation, earthing and electrical enclosure condition are checked. Warning devices, lights and travel alarms are examined, along with access platforms, walkways and fall protection on the crane and along the runway, and the safe working load must be legibly and correctly marked on the crane and the hook block.

Load testing

Proof load testing is carried out on new installations, after structural repair or modification, after relocation, after any change to the runway, and at the intervals that the client's specification requires. The load is applied at the percentage above safe working load that the applicable standard states, with deflection of the bridge measured and compared with the permitted limit, brakes and overload devices verified, and the structure examined after the test. Where the condition of a runway makes load testing inadvisable, itmad says so before the test and not during it.

Standards applied

Inspection follows the standard that the contract or governing authority specifies, most commonly ASME B30.2 for overhead and gantry cranes, B30.11 for monorails and underhung cranes, B30.16 for overhead hoists, B30.17 for cranes with an underhung trolley and hoist, ISO 9927-1 for crane inspection and ISO 4309 for wire rope, with BS 7121 Part 2 where the client works to British practice. Manufacturer inspection and maintenance schedules are applied alongside.

When inspection is required

Periodically, at the interval that the governing authority sets; on commissioning of a new installation; after relocation, modification or alteration of the crane or the runway; after structural or weld repair; after an overload, collision or derailment; where duty has increased beyond the classification that the crane was specified for; and before a facility acquisition or lease, as a condition assessment. Inspections are scheduled around production so that access to the crane and the runway is available.

What the client receives

An inspection certificate in the format that the governing authority requires, and a report that identifies each crane by number, capacity, span and location. Findings are recorded component by component with photographic evidence, and the condition of the runway and supporting structure is reported separately. Defects are classified by severity, load test results record the applied load, measured deflection and post-test condition, cranes are tagged on site, and the equipment register is updated where itmad holds it.

Frequently asked questions

Why are runway beams part of the inspection?

They carry the full crane and load reaction into the building, yet they fall outside both the crane inspection and the building inspection. That is where the significant findings usually are, so itmad reports on the runway and supporting structure separately.

What equipment does this cover?

EOT cranes, single and double girder, under-slung and top-running cranes, goliath and semi-goliath gantries, portal cranes, jib and pillar cranes, monorails and beam trolleys, and workshop, process and ladle cranes. The runway and supporting structure are inspected with the crane.

How are hoist brakes tested?

They are tested for holding capability under load and not merely observed to release. Overload protection is verified against known loads and not assumed.

Which standards apply?

Most commonly ASME B30.2, B30.11, B30.16 and B30.17, ISO 9927-1 for crane inspection and ISO 4309 for wire rope. BS 7121 Part 2 applies where the client works to British practice.

When is an overhead crane inspected?

Periodically, on commissioning, after relocation or modification of the crane or runway, after structural repair, and after an overload, collision or derailment. It is also done where duty has grown beyond the crane's classification and before acquiring or leasing a facility.

What if the runway is unsuitable for load testing?

Where its condition makes load testing inadvisable, itmad says so before the test and not during it. Deflection under load is measured where the runway's condition or history warrants it.