Safety for lifting equipment: Standard-compliant inspection and maintenance according to FEM and ISO 4309

1. Introduction: Importance of standards-compliant inspection

The operational safety of lifting equipment, such as cranes and winches, is a critical requirement in industrial production in the DACH region. Downtimes due to defective systems not only lead to production interruptions, but also pose significant risks to occupational safety. Regular, standard-compliant inspection and maintenance is therefore essential. Standards such as the DIN standards, FEM guidelines and the ISO 4309 define the necessary test intervals and criteria to ensure the structural integrity and functionality of the components. Failure to comply with these standards not only puts staff at risk, but also results in the loss of insurance claims and significant legal consequences for the company.

2. Scope and Applicability

These requirements apply to all lifting equipment used in the industrial sector. This includes overhead cranes, gantry cranes, chain hoists and rope hoists, which are used in a wide range of sectors - from heavy industry to automotive manufacturing to pharmaceutical production. The legal basis for the operation of lifting equipment in Germany is, in particular, the Industrial Safety Ordinance (BetrSichV) in conjunction with DGUV regulation 52 (formerly BGV D6). The application covers the entire life cycle of the system, from commissioning to decommissioning. Retrofitted components are also subject to the same strict requirements.

3. Core requirements: Summary of duties

In addition to the regular tests, the maintenance intervals specifically defined in the manufacturer's operating instructions must be strictly adhered to.

4. Impact on maintenance, procurement and documentation

Compliance with standards fundamentally transforms the MRO process. Maintenance needs to shift from a reactive to a preventive strategy. This requires complete documentation in an inspection book that must be kept during every inspection. When purchasing spare parts, the origin of the components is of crucial importance. It is essential to ensure that only spare parts are used that meet the specified technical requirements (e.g. strength class, material quality) and have the necessary certifications. The documentation requirement also requires that the declaration of conformity be updated when safety components are replaced.

5. Requirements for components and spare parts

Particular attention is paid to the so-called safety-relevant components. These include:

• Wire ropes: Must be checked for wire breaks, corrosion and deformations in accordance with ISO 4309:2017 and replaced immediately when they are ready for discard.
• Load handling equipment: Hooks, chains and slings must be CE certified and comply with applicable standards.
• Brake systems: Must be designed in accordance with FEM 9.683 and guarantee safe holding of the nominal load.
• Limit switches: Safety limit switches for lifting and lowering movements must be designed redundantly or monitored in a fail-safe manner.

For explosion-protected areas, ATEX conformity of all components is also mandatory.

6. Safety Officer Checklist

1. Ensure the validity of the annual UVV test sticker.
2. Visual inspection of all load-bearing devices (hooks, slings) for deformation and cracks.
3. Rope test according to ISO 4309 for wire breaks, wear and lubrication status.
4. Functional test of the emergency stop device from all operating states.
5. Checking the lifting and lowering limit switches for proper shutdown.
6. Control of overload shutdown using a defined test load.
7. Checking the braking device for wear and holding force.
8. Visually inspect structural welds for signs of cracking.
9. Checking the trolley rollers for wear and misalignment.
10. Check the rope pulleys for traces of entry and ease of movement.
11. Inspection of electrical cables for damage and insulation.
12. Checking the legibility and completeness of the nameplates.
13. Checking the lubricant levels and tightness of the gearbox.
14. Checking the strength of screw connections (tightening torque).
15. Check that the permissible load is correctly marked.
16. Verification of the completeness of the test book and documentation.

7. Common reasons for non-compliance

The following deficiencies are regularly identified during audits:

• Failure to observe the discard maturity of wire ropes in accordance with ISO 4309.
• Bridged or defective limit switches.
• Missing or outdated documentation in the test books.
• Use of unspecified spare parts (lack of CE conformity).
• Corrosion on load-bearing components due to lack of preservation.
• Incorrectly designed or incorrectly set overload protection devices.

8. Penalties and Liability

Failure to comply with the standards leads to serious legal consequences in the event of an accident. According to BetrSichV and BGB §823, this can lead to direct liability for those responsible. In cases of gross negligence, the professional association or insurance company often does not take over the settlement of the damage or takes recourse against the company or the responsible managers. Criminal law consequences are the rule in the event of personal injury. The burden of proof for compliance lies with the employer, which is why complete documentation is the only safeguard.

9. Conclusion

Compliance with standards such as FEM and ISO 4309 is not a bureaucratic option, but the technical basis for safe operational processes. As a specialized partner in industrial maintenance, UNITEC-D supports companies in selecting certified and standard-compliant spare parts. Avoid risks and rely on components that function reliably under demanding conditions. Discover our range of certified spare parts in our UNITEC-D E-Catalog.

10. References

• ISO 4309:2017: Cranes – wire ropes – care and maintenance, inspection and discarding conditions.
• FEM 9.683: Selection of engines for series hoists.
• DGUV regulation 52: Cranes.
• Industrial Safety Ordinance (BetrSichV) - Ordinance on safety and health protection when using work equipment.